Utility Cart

Cover some ground with this movable helper.

Photography by Brian Francis

Utility Cart

This utility cart features a stout frame with a folding handle that doubles as a support stand. A built-in storage rack keeps garden tools steady, and the oversized bin can take on big loads with ease. Large wheels allow you to move the cart in various conditions and terrain.

General Instructions

Cut and label the parts as needed, using the Cut List as a guide and adjusting for fit.

Step-by-Step

Prepare the handle assembly
- Lay out and cut the (01) upper handles and the (02) lower handles as shown in Figure 1. These parts are ripped from 1 x 4 stock.
- Drill the holes for assembly and for the dowel as shown in Figure 1.
- Attach each (01) upper handle to each (02) lower handle by placing a 1/4-inch washer between the parts and securing them with carriage bolts and lock nuts as shown in Figure 2. Tighten lock nuts to remove slack while still allowing the (01) upper handle to pivot freely.
Prepare the floor assembly
- Lay the (03) floor boards face down on a work surface, and mark a centerline across all four boards perpendicular to the long edges (see Figure 3).
- To determine the placement of the center (04) floor brace, measure 1 3/4 inches from the centerline, and draw a parallel line across all of the (03) floor boards. This will be the location for the edge of the center (04) floor brace.
- To determine the placements of the two outer (04) floor braces, measure in 1 1/2 inches from the ends of the boards, and then draw a pair of lines parallel to the centerline.
- Align the edges of the (04) floor braces to the lines you marked on the (03) floor boards, and attach them with glue and 1 1/4-inch screws.
Complete the nose assembly
- Repeat the layout instructions in Steps 2a-c for the (05) nose boards and the (06) nose braces. (See Figure 4.)
- Attach the (06) nose braces as described in Step 2d; however, the (06) nose braces should overhang the bottom (05) nose board by 3/4 inch.
Connect the floor and nose assemblies
- On a flat work surface, position the handle assembly as shown in Figure 2.
- Attach the floor assembly to the (02) lower handles using glue and 1 1/4-inch screws. Make sure that the ends and the sides are flush.
- Attach the nose assembly to the floor assembly by driving 1 1/4-inch screws through the (06) nose braces and into the edge of the floor assembly.
- Position the (07) handle brace flush with the ends and the sides of the (02) lower handle, and attach it with glue and 1 1/4-inch screws.
- Attach the (08) dowel to the (01) upper handles with glue.
Add the sides, tool holders, axel rod, and wheels
- Lay out the (09) upper sides, (10) middle sides, (11) lower sides, and the (12) tool holders as shown in the Part Details, and cut them to shape. Test-fit all parts, and adjust if necessary.
- Position all of the side pieces between the floor assembly and the nose assembly per Figure 5, and attach them with glue and 1 1/4-inch screws.
- Center one of the (12) tool holders on top of the (09) upper sides, and attach it with glue and 1 1/4-inch screws.
- Center the remaining (12) tool holder on the (07) handle brace, and attach it with glue and 1 1/4-inch screws.
- Thread the axel rod through the holes in the (02) lower handles. Place 1/2-inch washers on the ends of the axel rod followed by the wheels. Mark and cut the axel rod to length with a hacksaw, allowing room for the axel cap nuts.
- After cutting the axel rod to length, reassemble the axel rod, washers, and wheels, and then press on the two 1/2-inch axel cap nuts.
Apply finishing touches
- Stand the cart in the upright position, and lower the handle for the standing position. Clamp it in place.
- On both sides of the cart, drill a second 1/4-inch hole that passes through the (02) lower handle and into the (01) upper handle. Ream out the hole slightly to allow a carriage bolt to slide freely in and out of the hole.
- Attach a short length of chain to each (02) lower handle with a 1/2-inch screw, and secure the other end to a carriage bolt using a lock nut. These bolts serve as pins to lock the handle for the cart's standing position.
- Set all nails, and fill all nail holes. Sand smooth.
- Apply polyurethane, and let dry.

Good To Know

Cabot polyurethane and exterior stains help outdoor projects last through wear and tear.

Skill Set

Fitting Angled Parts:
If your angles are not perfect in this project, you can end up with large gaps between the sides and the floor and nose assemblies. When working with angled parts, be sure to test-fit before assembly and, if necessary, adjust by scribing and re-cutting the parts.

Illustration

All-Season Bench

Cut List

Part	Material	Size (in inches)	Quantity
(01) upper handles	1 x 4	3/4 x 2 1/2 x 27 1/2	2
(02) lower handles	1 x 4	3/4 x 2 1/2 x 36	2
(03) floor boards	1 x 6	3/4 x 5 1/2 x 24	4
(04) floor braces	1 x 4	3/4 x 3 1/2 x 21 1/4	3
(05) nose boards	1 x 6	3/4 x 5 1/2 x 22 1/4	3
(06) nose braces	1 x 4	3/4 x 3 1/2 x 17	3
(07) handle brace	1 x 4	3/4 x 3 1/2 x 24	1
(08) dowel	dowel	1 1/4 x 22 1/2	1
(09) upper sides	1 x 6	3/4 x 5 1/2 x 26 1/8	2
(10) middle sides	1 x 6	3/4 x 5 1/2 x 22	2
(11) lower sides	1 x 6	3/4 x 5 1/2 x 11	2
(12) tool holders	1 x 4	3/4 x 3 1/2 x 22 1/2	2
Finished Dimensions (including columns): Height: 46 inches (standing position) Depth: 19 inches (of bin) Width: 24 inches

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