Critique My Wood Cart Design

sansbury

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Feb 15, 2025
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I'm fitting out a new shop and trying to build good organization in from the ground up. Wood storage is one of the key items and because I'm a glutton for punishment I decided to try designing a mobile storage cart tailored to my situation. Before I drop $200 and many hours of build time I thought I'd throw the design up here for feedback.

My design goals were to provide mobile racking for 3-5 full sheets of 3/4 plywood and a limited amount of 8' boards, plus offcuts, while keeping the footprint to a minimum. This would be adequate to support one large project (for me) or two smaller ones plus leftovers, which feels like the right amount for me. I am a part-time DIYer so I don't have a need to inventory a lot of material.

I chose a 3x5' footprint as this seemed like a good compromise of size, capacity, and stability for handling 8' lengths and full sheets. This fits completely onto 3 4x8 sheets. Probably my biggest question is whether 3' is a little too narrow for stability, particularly if I had 3+ sheets of plywood on it since the load would be biased a bit off center. I *think* so, but this is why I'm asking :cool:

Assembly would be a combination of dominoes/screws and I *think* I've thought the sequence through so there are no impossible joints. The fussiest piece will likely be routing the cutouts in the upright frames so that they align well. These are sized so they could fit 6 or 8 inch boards. I added full-length shelves so that these could hold different lengths and make the alignment of the cutouts less critical. There is a little material left over that could be used to make more bin dividers or shelves. My thinking was that the rear could have one side for storing shorter lengths while the other has hangers for clamps and such.

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This is modeled in Fusion since the majority of my work has been more mechanical design than woodworking. Happy to share the model once it is finished.

Thanks in advance!
 

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I like it, especially the pass through shelves for boards.

Don’t know about using 6 casters since typically only three touch a flat surface at a time, unless there is a lot of flexibility in the structure.
Personally I’d go with just 4 larger diameter wheels and make the structure more rigid. Then add a shelf underneath between the casters to recover some of that space.
 
Personally I’d go with just 4 larger diameter wheels and make the structure more rigid. Then add a shelf underneath between the casters to recover some of that space.

That's fair... I guess with the kinds of loads this would have it's not going to be twisting or sagging that much? I was thinking 6 just because they're not that expensive. My floor is brand new and nice and flat so I don't need off-road capability :ROFLMAO:
 
What's the headroom in your shop area? If you have the space to stand your sheet goods on end, instead of edge, you'll save a ton of space.
 
How will you stop it moving on the casters when sliding material on and off?
Locking casters
The small lip at the front could be a weak spot if you're levering 8x4 sheets off it.
I thought about building that up with a couple strips of plywood screwed together. Would be more durable but I’ve seen multiple people build them this way so maybe it’s good enough?

What's the headroom in your shop area? If you have the space to stand your sheet goods on end, instead of edge, you'll save a ton of space.
11’ so I have room. If I wanted to go that way would you do anything differently? Build it taller/wider?
 
11’ so I have room. If I wanted to go that way would you do anything differently? Build it taller/wider?
I would cut the width down to 48 to 52...somewhere in there. Maybe a little taller and a little less angle. Make sure that the long solid wood stock on the back and the sheet goods in front don't run into each other.

I mention this because I built a somewhat similar rack. My experience has been that I almost never have full sheets in the rack. Full sheets come in to my shop when they're needed, so it's the partials that need racked. Either way works...it's just that maneuvering something 8' long through a typical DIY shop can be a challenge.
 
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