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PantoRouter Cart

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Project by JL7 posted 05-20-2018 05:26 PM 1652 views 3 times favorited 14 comments Add to Favorites Watch

I picked up a new toy recently and needed a spot to use it. The cart frame is 80/20 style aluminum tubing which I got for free from the recycle bin at work. This is the same stuff I used for my workbench, router table and table saw builds, as well as the sliding table on my drum sander. So this fits into the shop plan nicely.

The build dimensions were completely dictated by the aluminum pieces at hand:

The MDF side and back panels (and center panel not shown here) are rabbeted on both faces and all four sides to lock in place:

The top and bottom butcher blocks are made of reclaimed Hard Maple gym floor:

These match the top I made for my shop cart a few years back:

The bottom butcher block was then notched and rabbeted to lock into the frame rails:

Drawer boxes use box joints cut on the PantoRouter and pinned with 1/4” Walnut pins:

Turns out the tongue on some of the flooring cutoffs was just the right height to secure the top butcher block to the frame, using the tongue inside the groove in the aluminum channel:

Only materials purchased for the build are the drawer slides and the industrial style leveling casters:

The open space at the bottom is just big enough to store the PantoRouter so I can use the cart for other purposes as well.

Thanks for looking!

-- Jeff .... Minnesota, USA





14 comments so far

View Dutchy's profile

Dutchy

3153 posts in 2372 days


#1 posted 05-20-2018 05:50 PM

View WhereDidIPutThat's profile

WhereDidIPutThat

43 posts in 1540 days


#2 posted 05-20-2018 06:56 PM

Nice cart. She sure looks sturdy. Are those casters the foot master or the Wood River knockoffs?

Nice assembly table too

-- palette wood connoisseur

View CFrye's profile

CFrye

10487 posts in 2043 days


#3 posted 05-20-2018 09:14 PM

Awesome job, Jeff! Did you get the cabinet frame already assembled or the pieces from the recycle bin?
Great idea using the tongue on the flooring for a movable cleat. Thanks for sharing.

-- God bless, Candy

View SPalm's profile

SPalm

5325 posts in 4086 days


#4 posted 05-20-2018 10:54 PM

You go Jeff.
Amazing. Simply amazing.

Steve

-- -- I'm no rocket surgeon

View boxcarmarty's profile

boxcarmarty

16741 posts in 2564 days


#5 posted 05-21-2018 12:03 AM

Sweet…..

-- My mind is like lighting, one brilliant flash, then its gone.....

View JL7's profile

JL7

8690 posts in 3169 days


#6 posted 05-21-2018 12:06 AM

Hey all, appreciate the comments!


Nice cart. She sure looks sturdy. Are those casters the foot master or the Wood River knockoffs?

- WhereDidIPutThat

They are the Wood River knockoffs. I have the Foot Masters on a few of my other things, but only becasue I got them free…..they are spendy!


Awesome job, Jeff! Did you get the cabinet frame already assembled or the pieces from the recycle bin?
Great idea using the tongue on the flooring for a movable cleat. Thanks for sharing.

- CFrye


Candy – the frame started as 6 (i think) rectangular frames, all the same size, so I took it from there..

-- Jeff .... Minnesota, USA

View oldnovice's profile

oldnovice

7336 posts in 3571 days


#7 posted 05-21-2018 01:05 AM

I have a lot of that recycle bin aluminum and use it as various purposes like a temporary large (12’ long), table for sanding and finishing outdoors.
I will be using some to make my own version of a B&D Workmate, larger, height adjustable, and easier to move!

You put yours to good use as that makes a nice cart!

-- "I never met a board I didn't like!"

View Gary's profile

Gary

9386 posts in 3637 days


#8 posted 05-21-2018 01:24 AM

Looks ok….. send it to me and I’ll check it out

-- Gary, DeKalb Texas only 4 miles from the mill

View woodbutcherbynight's profile

woodbutcherbynight

5720 posts in 2613 days


#9 posted 05-21-2018 03:13 AM

Looks good, heck of a build. Very nice!

-- Live to tell the stories, they sound better that way.

View helluvawreck's profile

helluvawreck

32087 posts in 3070 days


#10 posted 05-21-2018 01:02 PM

Wow! This is a wonderful cart. It will be an outstanding addition to your shop. My brother and I used to have a large molding plant with a machine shop and I use to collect machine parts and surplus machinery for our shop. This project uses what I call first class salvage. You did a fine job on this piece. Congratulations!

-- helluvawreck aka Charles, http://woodworkingexpo.wordpress.com

View Calmudgeon's profile

Calmudgeon

173 posts in 1631 days


#11 posted 05-21-2018 02:08 PM

Nice build incorporating some real ingenuity.

Pardon me if this is a stupid question, but how are the aluminum extrusions fastened to one another?

-- "As are the things we make, so are we ourselves." - Lin Yutang

View JL7's profile

JL7

8690 posts in 3169 days


#12 posted 05-21-2018 04:05 PM

Thanks again folks for all the nice comments, appreciate it:


Nice build incorporating some real ingenuity.

Pardon me if this is a stupid question, but how are the aluminum extrusions fastened to one another?

- Calmudgeon


If you scroll down a bit in this blog HERE – I show the fastening process.

-- Jeff .... Minnesota, USA

View PantoRouter's profile

PantoRouter

2 posts in 1142 days


#13 posted 05-24-2018 12:42 PM

Nice cart! The aluminum extrusions are a fast way to build and you’re very fortunate to have access to the otherwise recycled pieces. We love up-cycling.

With your permission, we’ll add your cart to our www.PantoRouterUSA.com website to inspire other PantoRouter users. People are doing amazing work with the PantoRouter and we’re trying to share as much as possible so others can see the potential for their own projects.

Happy PantoRouting!

Mac

-- Woodworking joinery with the PantoRouter is faster, easier, more accurate and more fun!

View JL7's profile

JL7

8690 posts in 3169 days


#14 posted 05-24-2018 02:26 PM

Hey Mac,

That would be fine. Please let me know and I can send the original photos, this site resizes them. Either way, appreciate the comments and your customer service (you sent me out the replacement follower next day on your dime). Sure appreciate that!

-- Jeff .... Minnesota, USA

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