Prior to building this project I toted my air compressor around in a wheel-less bin. The pressure the air compressor exerted on the bins lid and sides caused it to slowly fracture at various points. Another issue I was experiencing with my air compressor storage was its ease of mobility. I either had to drag it around or leave it in a location where it could be easily utilized in all areas of my shop. With these issues in mind I sought to create a mobile cart that would make using my compressor more convenient. My new cart has wheels, trays to store accessories, and doesn't take up a lot of space!
This entire project is made from a single piece of 1/2" Birch plywood purchased from a local supplier. Since I didn't need the entire sheet I cut the plywood down to make it more manageable. To accomplish this I used a straight edge clamp and my circular saw. To further reduce the sheet of plywood and rough out the individual pieces I used my table saw. Finally, I reduce the pieces of this cart even further using my table saw cross-cut sled. This ensures that everything is square and identical in length.
Both the lower and upper trays are tapered. Since the tapers are identical to one another I decided to use blue painters tape to gang them together. This allows me to execute both cuts simultaneously producing two identical pieces. Because I don’t have a tapering jig for my table saw I opted to use my band saw. I have it set up with a half inch blade which cuts surprisingly clean through this plywood.
To prevent chipping of the thin birch veneer I sanded all the sharp edges with my random orbit sander. Once finished I started assembling the trays using glue and 1” brad nails. Given that the pressure exerted on these trays is minimal, the glue and brads should be sufficient.
The supports for each tray are made from kiln dried dimensional 2x4 lumber. I cut each support to rough size using my miter saw then cut each support piece to length using my crosscut sled. This is overkill, I know...
To attach the supports to the trays I squared each one individually to the bottom tray. I used a brad nailer to hold the trays in place then secured them using 1 1/4" screws. The same procedure is followed for the opposite side of the lower tray and both sides of the upper tray.
With that the basic construction is finished. All that’s left to do is attach 4 swivel castors to the bottom to make it mobile. I added blocks to the areas the castors will be attached to provide extra support.
I used 2” castor wheels attaching them using 1” pocket hole screws. The castors on the backside of the cart are locking swivel castors which prevent the compressor from moving across the floor as the compressor charges.
To give the compressor hose a place to be stored I found large hose hooks at the home store. These hooks had a large enough radius to accept the entire hose and still have room to spare. You can pick up hooks like these at most home stores in various configurations.
This mobile cart was a great solution to my air compressor storage problems and has already come in handy numerous times in my work shop. In a small garage workshop mobility is key and I have personally made it a goal to make as much of my shop furniture and tools mobile. Thank you for reading and watching this tutorial and any other content you may have seen.
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