Flip Top Tool Cart

My woodshop consists of my garage. Of course I have 2 cars, two dirt bikes and 3 active kids, so there’s a little work needed just to get my woodshop set-up.

I was searching the web for ideas to best store 2 of my heaviest bench tools, which just take up shelf space and are a pain to move around. I saw several iterations of the flip top concept, so I intergrated portions of a few designs I found.

The tools are a Dewalt planer and a Craftsman sanding station. Both weigh about 80+ lbs. I use the sanding station more frequently.

I only purchased a half sheet of 3/4” maple ply and 1/2” MDF. I had leftover birch ply from other projects. I’ve been on a kick lately to try and re-use or recycle wood from old furniture from my house or stuff I see in town on the side of the road on “general” garbage day. No, I’m not a trash picker. I’m gainfully employed. Anyway, the trim and drawer facia are planned down maple from a bunk bed my son out grew.

The flip top is a sandwich of 1/2” birch ply, 1/2” MDF and 1/2” birch ply. I used a 1/2” round stock from a big box store as the pivot and pinned the ends to the vertical sides. Therefore the top pivots on the fixed round stock. The ends of the round stock are hidden with the “bunk bed” trim.

I used the half sheet of maple ply for the sides. I was carefull to measure the clearance needed to fully rotate both tools which was 19”. I gave myself 19.5”. I needed the working surface to be about 34” off the floor since I’m 6’2” and like it taller than typical working height. In lieu of having to add some sort of bracing if my cart was only 2 sides and a bottom, I decided to add a drawer. This would give me two horizontal supports and a solid back for stability. Therefore I added a 24” deep drawer which is the width of the cart and 9” tall. Plenty of storage.

There were plenty of good ideas for latching the flip top in place. Again I chose a blend of those ideas and notched the MDF (prior to glue-up) in all 4 corners and uses a 1/2” x 4” eye bolt which pivoys on a short lag bolt. This came out slick. I’ll look to come up with a special know instead of the standard 1/2” nut. But you don’t need to tighten more than hand tight.

I purchased 200# fully locking casters for all corners. Be sure to use “total locking” style which locks rotation and swivel. They cost $9 each on eBay.

That’s my story.