Let’s Build a Scrap Wood Storage Cart!

Any time I do a project with wood, I have extra pieces. Over the years, I have stacked the wood sheets along a wall in the garage and stored pieces of trim in boxes. As you can see in the pics below, I have lots of scrap wood. This doesn’t even include the wood stored outside under our deck! This year, when we were organizing our garage, I decided to make a storage cart to hold all these extra pieces. I did a little research on YouTube to get ideas on how to go about building a cart that would suit my needs. Once I knew what I wanted, I headed to Home Depot to pick up supplies.

Below is a picture of the supplies after I cut the 2 x 4″ boards for the base. I bought a sheet of particle board at Home Depot. It was in the 70% off cart and had a bit of damage on it. Since it was only $10, I didn’t mind the damage. The 2 x 4 boards were also in the discount cart. I bought 4 locking casters but I feel like 2 locking ones and 2 regular ones would have been sufficient. My plan was to initially use a 1 x 6 board as a lip on the side of the cart that will hold sheets of wood but ended up using a 14″ piece of particle board that I had on hand. **FYI: If I were to build another storage cart, I would use plywood**

Supplies Used

• 1  4’ x 8’ sheet of particle board or plywood
• 1  4’ x 14” piece of particle board or plywood
• 2  2” x 4” boards
• 1  2” x 2” board
• 2” & 2 1/2″ star head screws
• 4  casters
• 16 L brackets (optional if using plywood)
• Clamps
• Paintbrush
• Miter Saw
• Skill Saw
• Kreg tool
• Drill with drill bit & screwdriver bit
• Preserva Wood

Step 1 – Cutting wood

Since the space where my cart would sit was limited, I decided to make it 4′ long by 20″ wide. With a 4′ width, it would make for fewer cuts since the particle board comes in 4′ width. I took advantage of the fact that Home Depot will cut wood for you. The sign states that they will do one cut but more often than not, they will cut whatever I ask which is using just two cuts. This time, I asked if the employee would be able to cut the sheet into four lengths – 3 1/2′, 20″, 20″, 14″ which would be 3 cuts. He agreed to do so which made it SO much easier for me!

When I got home, using a miter saw, I cut one of the 8′ 2 x 4 boards in half then cut the second board into four 17″ pieces and four 2″ pieces. I also cut the 2 x 2 in half.

Step 2 – Building the base

To ensure the base was the right size, I set the pieces of 2 x 4 on the 20″ piece of particle board that they would be attached to. Using clamps, I attached metal corner pieces then secured the sides to the crossbars with 2 1/2″ screws. With the base support done, I flipped it over and attached the sheet of particle board using 2″ screws.

Step 3 – Attaching the casters

I flipped the base over again to attach the wheels. To create a wider base for the casters, I screwed a 2″ piece of 2 x 4 to the inside of each corner of the base. I then attached one caster to each corner.

Step 4 – Adding the center support

Once the base was complete, it was time to decide how deep I wanted the storage bins to be and/or how much space I needed for sheets of wood. I have more trim scraps than sheets of wood, so I decided on a depth of 10″ for the storage bins. Now that I had my dimensions, I could attach the 3 1/2′ piece of board to the base. Using a kreg tool I made 6 holes along the bottom edge of the board. To hold the board upright while I secured it to the base, I clamped the 2 x 2 boards to the base leaving enough room between them for the width of the board. I installed all 6 screws but when I removed the 2 x 2 supports, I found that the screws were not strong enough to securely hold the board. Hubby suggested I use L brackets to give it more support. I attached 2 L brackets on either side of the board which was enough to make it nice and sturdy! (FYI: If you use plywood, the screws will be strong enough to hold the board)

Step 5 – Building the storage bins

Next, I cut the dividers for the storage bins. Using a skill saw, I cut 4 pieces from the second piece of 20” particle board each 10” wide. I wanted the front of the bins to be shorter, so using a straight edge, I marked an angle from the 20” length to 14” then made the cut with the skill saw. Since I knew that securing particle board with screws didn’t work well I attached 2 L brackets to each of the boards and then attached them to the center support and base. To finish the bins, I attached the 14″ piece of particle board to the front of the uprights by using 2 L brackets on each end and a couple of screws into the front of the dividers.

Step 6 – Attaching a lip

To keep the pieces of scrap boards from sliding off the cart, I attached a piece of particle board that I had on hand. I had initially thought I’d use a 1 x 6 but since I had a spare piece of particle board, I used it instead. I placed the bottom of the board even with the bottom of the 2 x 4 so I could use screws to secure it well. I then used L brackets on each end for added strength.

Step 7 – Sealing the wood

YouTube Video of the process

Finished storage cart

I cannot believe how quickly this cart came together! I spent a little less than 4 hours on the build & sealing. If it weren’t for the snafu with the particle board and screws, it would have been even faster. It is the perfect size for all of the scrap wood that I had (except the smaller pieces of trim which I hadn’t planned to include) and even fits in the space by the back door. The cost of the cart was around $70. As I said, the sheet of particle board was only $10 but then I spent an additional $20 on L brackets so I could have bought plywood instead which would have saved time and frustration. Also, if you order the casters & L brackets online, you’ll probably get a better price than buying them locally.

Before, During, After

Instructions using particle board

• To create the base:
• Cut one 2 x 4 in half so you have two boards that are 4’ each
• Cut four pieces from the second 2 x 4, each piece 17”
• Cut particle board/plywood into four pieces:  3 ½’, 20”, 20”, 14”
• You will need an additional piece of plywood measuring 14″ x 4′
• Assemble the 2 x 4 pieces into a frame with the 48” pieces along the sides with 17” pieces as crossbars
• Cut four pieces 2” pieces of 2 x 4 & attach one to each corner of the frame
• Attach a sheet of 20” x 4’ particle board/plywood to the frame using screws
• Turn the base over and attach the 2” pieces of 2 x 4 in each corner
  • These will be used to attach the casters
• Using screws, attach one caster to each corner
• Turn base over to work on the upright pieces
• To create center support:
• Cut 2 x 2 in half – this will be the support for the 3 ½ x 4’ particle board sheet while you attach it to the base
• Decide where you want your center support board to go
  • I attached mine 8″ from one side
• Using screws, attach 2 L brackets on each side of the particle board along the edge that will be attached to the base
• Secure one of the 2 x 2 boards to the base using clamps
  • If working with a partner, using the 2 x 2 supports is not needed
• Stand the plywood sheet next to the 2 x 2 x 4’ board and attach the two L brackets to the base using screws
• Remove 2 x 2 board
• Attach the two L brackets on the 2nd side of the particle board to the base
• Storage bin uprights:
• Cut 4 pieces from the particle board  20” x 10” x 14”
• Attach one L bracket at the top of each board along the 20″ edge and another L bracket at the bottom on the other side
• Attach the 4 upright pieces to the larger section of the base using screws
• End caps:
• Cut two 14″ x 4′ pieces of particle board
• Attach to the front of the storage bin uprights using 2 L brackets on either end
• Attach 2nd piece of particle board to the 2nd side of the base using screws through the 2 x 4 and L brackets on the ends
• Seal particle board with Perserva wood or another oil-based clear sealer

Instructions using plywood

• To create the base:
• Cut one 2 x 4 in half so you have two boards that are 4’ each
• Cut four pieces from the second 2 x 4, each piece 17”
• Cut plywood into four pieces:  3 ½’, 20”, 20”, 14”
• You will need an additional piece of plywood measuring 14″ x 4′
• Assemble the 2 x 4 pieces into a frame with the 48” pieces along the sides with 17” pieces as crossbars
• Cut four pieces 2” pieces of 2 x 4 & attach one to each corner of the frame
• Attach a sheet of 20” x 4’ particle board/plywood to the frame using screws
• Turn the base over and attach the 2” pieces of 2 x 4 in each corner
  • These will be used to attach the casters
• Using screws, attach one caster to each corner
• Turn base over to work on the upright pieces
• To create center support:
• Cut 2 x 2 in half – this will be the support for the 3 ½ x 4’ plywood sheet while you attach it to the base
• Using a Kreg tool, drill 5 holes along the edge that will be attached to the base on one side of the plywood
• Decide where you want your center support board to goI attached mine 8″ from one side
• Secure one of the 2 x 2 boards to the base using clamps
• Secure the second 2 x 2 the width of the particle board/plywood from the first 2 x 2If working with a partner, using the 2 x 2 supports is not needed
• Stand the plywood sheet between the two 2 x 2 x 4’ boards and attach it to the base using screws
• Remove 2 x 2 boards
• Storage bin uprights:
• Cut 4 pieces from the plywood  20” x 10” x 14”
• Using a Kreg tool, drill 2 holes along one side of the 10″ side of each of the upright pieces
• Attach the 4 upright pieces to the larger section of the base using screws
• End caps – plywood:
• Cut two 14″ x 4′ pieces of plywood
• Attach to the front of the storage bin uprights using screws
• Attach 2nd piece of particle board to the 2nd side of the base using screws through the 2 x 4

For your convenience

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