For the Shop — "A Large Panel Storage Cart"

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   This is the A frames with the 2 X 6 with 10o beveled sides at the top. I will admit that it would topple over in an instant with any gust of wind.
   It is up so that I can center this framework on the base.

  I have clamped a 2 X 4 to the base to help me hold the legs as I screw them to the base.

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   Fastening each of the legs to the base was quite an easy routine. I pulled the leg to the strip of wood and pre-drilled a hole that was diagonal to the upright. Then I screwed in a 4" deck screw. I really do not need much strength at this point — mostly it is needed for positioning.

   The A-frame skeleton is in place, and I have put two sheets of melamine board on the frame. I am using 1 1/2" narrow crown staples to tack these in place.
   This is a heavy rack already but rolls very easily on the large wheels. Next, I have to put angles on the floor of the cart and then boards on which panels will rest.

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   With the sides up and at 10o, I want to cut quite a few wedges to support the side tray at an angle that will allow the panels to rest against the main side.
   It should be 10o, but I find it easier to clamp a SquareIt to the side and trace the line I need.

   I am simply darkening the line I need to cut.

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   I could have created a simple jig for the table saw but I set up a few clamps and some blocks and was in business with the Festool Circular saw and multifunction table. Since the saw cuts a line right at the edge of the guide, I simply positioned that sample block I drew and then eased blocks against it and clamped them in place.
   By the way, I have had a cabinet makers blade on the saw since the beginning. In cutting the 2 X 4 wedges, I decided to switch to a general purpose/rip blade. It was a wise move. It cut these wedges like slicing butter.

    This view should give you a better idea. I cut a bunch of 2 X 4's to length. In my left hand, I am pushing one of the "blanks" against the other so that the new block is snug against both clamp blocks.
   Since the wedge is so small, the table's fence does not "stop" the wedge I am cutting, so I have placed the right clamp on a piece of scrap that stops the wedge from being pushed out after the cut.

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   Here are the wedges being glued  and stapled in place. I initially was going to cut 16 wedges and space them the same as the 8 frame members. When I started stapling them in place, I decided to use all 16 on this side and cut another 16 for the other. They were so easy to cut, this made more sense. For information, I did use Roo Glue for attaching the wedges to the white melamine.

    I have added more glue to the tops of the wedges and have laid the white melamine piece in place. This was a scrap and is wider than I needed but it is simple to cut the piece to the right width using the long guide and the Festool circular saw. I also still have the general purpose blade on. I wanted to see how "rough" a cut it would give me. I was surprised. There was very little chipout on the guide side — and not too much more on the outside of the blade. I think it has a lot to do with the saw being firmly held on track.

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   I am adding a strip of 1 1/2" oak to serve as a ledge and keep the panel goods on the cart. I am pre-drilling with a stepped drill for use with the confirmat style 7mm screws. Those plus yellow glue will give me a ledge that should be indestructible.
   For information, the oak is being attacked to the edge of the white melamine coated board so I can use any standard wood glue.

     I could have done a beautiful job of rounding over the oak strip with the router, but I chose the block plane. It is so fast and chamfers just enough to take the sharp edge away.

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   Well, it is done and I have a lot more scraps to place on this side. The other side is for full sheets, and I have loaded it already. On the right end, there are the stationary wheels. The swivel wheels are on the left end. To get to the other side, I can simply pull that end out. It comes out easily to about 45o angle from the wall which is enough for me to have good access to the other side.
   This cart is very heavy but is easily maneuvered and has a low center of gravity. There is no tilting when I pull it out from the wall.

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