Drill Press Storage Cart

Drill Press Storage Cart Richard Hicks on July 22, 2013 Drill Press Storage Cart

Drill Press Storage Cart My Inspiration ShopNotes Issue 128 Changes Used casters instead of wheels Didn t build the drill press mobile base Modified the dimensions to fit my needs and drill press Added anti-tip safety device Richard Hicks on July 22, 2013

Step One Establish the dimensions: Your drill press Post diameter Table height in normal use Base dimensions Storage needs (largest and smallest items to be stored) Parts that you will use to build the cart Casters Drawer slides

20 column to edge of table 32 from floor to tips of the handles

4 Column diameter 4 ½ collar diameter at 4 from floor 4 high Base is 13 wide

3 inch Caster Dimensions 4 high Mount is 2 ½ wide Source: Harbor Freight Cost $3.99 per caster Mount is 3 ½ long

18 Drawer Slide Dimensions Full Suspension drawer slide, 100# capacity 17 ½ long and 1 ¾ wide Source: www.woodworkershardware.com Cost: $5.90 per pair (quantity 10 price)

Drill Press Storage Cart Richard Hicks on July 22, 2013 Banding the Plywood edges I like using plywood, but I don t like the plywood edges. I applied pre-glued, heat activated, edge banding on all of the exposed edges before assembly. I use an old iron (on dry, cotton heat setting) to heat the edge banding adhesive and a round shank Phillips screwdriver to press the adhesive strips in place. Banding adds about 1/64 to the size of the piece. Source: www.woodworkershardware.com - $22.05 for 7/8 x 250 feet

Drill Press Storage Cart Richard Hicks on July 22, 2013 Banding the Plywood edges I used a FastCap Macro Flush Cutting Trimmer to trim the ends of the banding at the corners. Source: www.woodworkershardware.com - $12.66

Drill Press Storage Cart Richard Hicks on July 22, 2013 Banding the Plywood edges I used a FastCap Quad Pro Trimmer to trim the edges of the banding. Even though it s made to trim both sides at once, I found it worked better to trim each side separately. I used a sanding block with 400 grit paper to sand the edges after using the trimmer. Source: www.woodworkershardware.com - $20.35

Drill Press Storage Cart Richard Hicks on July 22, 2013 Cut List for the Cabinet * Note: Measure your plywood measurements are based on full ¾ thick Plywood

Drill Press Storage Cart Richard Hicks on July 22, 2013 Cut List for the Drawers * Note: Measure your plywood measurements are based on full ¾ thick Plywood

Plywood Layout Sheet

¾ Plywood Sheet One 77 1/8 8 C - Side 23 ¾ x 19 D - Side 23 ¾ x 19 23 ¾ x 9 1/4 F Cubby Back 23 ¾ x 9 1/4 G Cubby Back 23 ¾ x 10 H Cubby Side 23 ¾ x 10 I Cubby Side 23 ¾ X 18 4 DF-5 25 x 7 E - Back DF-4 25 x 4 ½ 23 ¾ 23 ¾ x 26 1/2 DF-4 25 x 4 ½ J Caster Support 29 x 5 X 15 DF-2 25 x 3 ½ DF-1 25 x 3 ½ K Caster Support 29 x 5 26 ½ 25 29 80 3/4

D3-A 16 1/2 x 3 ¾ Plywood Sheet Two 8 A - Base 26 ½ x 29 A - Top 26 ½ x 29 26 1/2 X 38 4 D3-A 16 1/2 x 4 D5-A 16 1/2 x 6 1/2 D3-B 24 x 4 D5-B 24 x 6 1/2 D3-A 16 1/2 x 4 D3-B 24 x 4 D3-A 16 1/2 x 3 D5-A 16 1/2 x 6 1/2 D2-B 24 x 3 D5-B 24 x 6 1/2 L Shelf D3-A 16 1/2 x 3 D3-A 16 1/2 x 3 D4-A 16 1/2 x 4 D2-B 24 x 3 D1-B 24 x 3 D4-B 24 x 4 10 x 8 ½ M Shelf D3-A 16 1/2 x 3 D4-A 16 1/2 x 4 D1-B 24 x 3 D4-B 24 x 4 10 x 8 ½ 16 ½ 16 1/2 24 24 81

¼ Plywood Sheet One 83 Drawer Bottom 1 23 ¼ x 17 ½ Drawer Bottom 2 23 ¼ x 17 ½ Drawer Bottom 3 23 ¼ x 17 ½ Drawer Bottom 4 23 ¼ x 17 ½ Drawer Bottom 5 23 ¼ x 17 ½ 23 ¼ x 7 24 ½ x 96

Edge Banding Edge Banding Edge Banding 5 radius Edge Banding A & B - (Top and Bottom) 26½ W x 29 L Edge Banding

Edge Banding Edge Banding Pocket Holes Pocket Holes C & D - (Right & Left Sides) 19L x 23¾ H Decide the size drawers you need (I used (2) 3½, (2) 4½ and (1) 7 drawer). Draw the slide mounting guide lines on both side panel (C) and (D).

Edge Banding Edge Banding Pocket Holes E - (Back) 26½ L x 23¾ H

Edge Banding Edge Banding Shelf Pin Holes Shelf Pin Holes E - (Back reverse side) 26½ L x 23¾ H Note: Match shelf pin hole spacing to parts H & I (Cubby Sides)

Edge Banding Edge Banding Pocket Holes Pocket Holes F & G (Cubby Back L & R) 9¼ L x 23¾ H

Edge Banding Edge Banding Pocket Holes Pocket Holes Shelf Pin Holes Shelf Pin Holes H & I (Cubby Side L & R) 10 L x 23¾ H Note: Match shelf pin hole spacing to part E (Back)

Edge Banding Edge Banding J & K Caster Support (L & R) 5 W x 29 L

Edge Banding Edge Banding L & M Cubby Shelves 8 ½ W x 10 L Edge band all four sides

Six Alignment Blocks 5 x 5 with ¾ dados Optional

The leftover plywood

Vacuum attachment on Kreg K-3 Jig

Installing left side (D) Clamp the side in position, drive three screws, remove the screws, add glue, re-clamp and re-screw.

Installing right side (C) Clamp the side in position, drive three screws, remove the screws, add glue, re-clamp and re-screw.

Installing the back (E) Clamp the back in position, drive three screws, remove the screws, add glue, re-clamp and re-screw. Screw the sides (C) and (D) to the back (E). The alignment blocks will help keep the pieces in place while you screw them together.

Installing the left cubby back (F) Clamp the Cubby back (F) in position, drive two screws on the bottom and two screws on the side, remove the screws, add glue, re-clamp and re-screw.

Installing the right cubby back (G) Clamp the Cubby back (G) in position, drive two screws on the bottom and two screws on the side, remove the screws, add glue, re-clamp and re-screw.

Installing the cubby sides (H) & (I) Clamp the Cubby side (H) in position, drive two screws on the bottom and two screws on the side, remove the screws, add glue, re-clamp and re-screw. Repeat for cubby side (I).

Install the drawer slides on both sides (C) and (D).

Installing the bottom (B) Turn cabinet upside down and install the bottom (B) panel. I used glue and secured the panel with brads. Next, add the caster supports (J) & (K) along each side of the cabinet.

My drawer sizes are: Building the Drawers (2) 24 x 18 x 3, (2) 24 x 18 x 4 and (1) 24 x 18 x 6 ½ The drawer fronts are: (2) 3½ x 25. (2) 4½ x 25 and 7 x 25 I used simple braded and glued butt joints, but reinforced the joints with dowels. * Note: Measure your plywood measurements are based on full ¾ thick Plywood

Building the Drawers After the glue dried, I drilled holes and glued ¼ dowels in the corner of each drawer.

Installing the Drawers After the drawers dry, install the other part of the drawer slides and install the drawers.

Installing the Drawers Install the drawer handles on the drawer fronts and then attach the fronts to the drawers. I used quarter spacing between the drawers (used a quarter as a measuring spacer between the drawer fronts).

Installing the Drawers The completed drawer installation.

Installing the Drawers After all the fronts are installed, remove the drawers one at a time and install the bottoms. I used ¼ melamine coated MDF and secured the bottom panel with brads. Reinstall the drawers.

Installing the casters Install the casters (the swivel casters go in front) and secure with 1 ½ screws and washers. Position the front casters so they don t protrude out from the front of the cabinet (eliminates a possible tripping hazard).

Installing the anti-tip safety feature As a safety measure, I installed an anti-tip brace across the top of the back of the cabinet. That s in case more than 1 heavy drawer gets opened at the same time. I used T-nuts through the top panel and knobs with 5/16 x 16 threaded studs.

The Completed Storage Cart