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I have been in my
"new" shop for almost a year. At the time of the move, I had planned to make a
cart to hold 4 X 8' panels. I haven't done this yet, and the panels and scraps just keep
growing. Other than taking up more and more space, the biggest problem is that I can't get
to the sheets that are closest to the wall even if I knew what was back there.
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I have seen a lot of carts
that I liked, but in most cases I had one problem I didn't want to use small shop
casters and I couldn't afford the big casters that would allow the weight to be moved
effortlessly...even over sawdust and cords.
Then last weekend, I visited my local woodworkers' store and saw 4 large,
balloon wheel sets on sale.
$60 later, I had what I wanted and decided to "sneak" in this shop
project, even though there are 3 or 4 others in the works.
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I have ordered lumber
which will be delivered in the next hour so I start making the internal frames. I am using
pressure treated 2 X 2's because I ordered more than I needed when I did the deck job a
month ago. I have cut them to 4-foot lengths and have cut the stringers with 10o
angles. The top one, is only a piece to serve as a jig. I will cut a 2 X 6 with 10o
sides that will run the 8 foot length.
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I have assembled 8 of
these A-frames and just in time. The lumber has been delivered. I set up two 2 X 4's that
will simulate the base of the cart. I know that it will be 8 feet long, but it is the
width that I am trying to figure out now. I decided that 3' would make a good width. That
will hold a lot 16 - 3/4" sheets. It isn't the sheets that accumulate. It is
always the scraps. Some of the scraps will be stored inside the "A". I will
build a better shelf for the cut-offs at the chop saw. Mostly, I will have to learn to
"manage" the scraps better.
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I have cut eight
"studs" to 33" length, In fact this floor of the cart is no different in
structure that the house or deck. I have two studs in each end spaced to meet the spacing
of the mounting holes of the wheels. The rest are just put to approximately 13"
centers. No inspectors will cite me code on this floor.
I was planning to half-lap all around and Sal brought me back to reality.
Nailing them will make a plenty strong base.
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I am drilling 1" holes
for countersinking the heads of 3/8" nuts and washers that will anchor the wheels.
The hole itself is 1/2".
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It took some time to get all the holes
lined up and the bolts tightened, but all the wheels are now in place.
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Sal and I have brought one of the
three 4' X 8' 3/4" melamine panels in and have positioned it on the mobile base. We
aligned one long side and one short side, and I am now trimming off the excess. And, yes,
I am using the Festool circular saw and the shorter guide for making the short cut. In
this instance, we were able to use two of the Festool clamps that fit into the guide
channels.
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On the 8 foot side, I used
the long guide but was not able to use the clamps. The wheels were in the way. With
Sal holding one end, I made the cut. Even though the white melamine is a slippery surface,
the three rubber strips on the guide base keep a pretty good hold the saw tracks
right down the side. That is so much easier that using the router and a panel bit
not to mention much less particle board dust in the air. With the Festool circular saw,
the Festool vacuum sucks almost all this nasty dust up.
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