Prior to building this project my air compressor sat in a bin that it was too large to fit in. Due to the pressures that the air compressor exerted on the bins lid and sides the bin slower but surely started to crack and fracture at various points. The other major flaw to storing my air compressor the way it was being stored was that it wasn’t very mobile. This project is the answer to all my air compressor woes. My new cart is mobile and has a small tray that floats above the compressor for storage of little compressor odds and ends.
This entire project is made from a single piece of half inch Birch plywood which I purchased from a local hardwood supplier. Since I don’t need the entire sheet to complete all my cuts I decided to cut it down to make it a little more manageable. I’m using a straight edge clamp and my circular saw to do this.
To further reduce the sheet of plywood and rough out the individual pieces that make up the trays of this cart I used my table saw.
Finally, I reduce the pieces of this cart using my table saw cross-cut sled to ensure that everything is square and identical in length.
Both the lower and upper trays of this cart are tapered and since the tapers need to be identical to one another I decided to use some blue painters tape to gang them together. This will allow me to execute the cuts needed for the taper on both pieces at once ensuring that they are identical.
Because I don’t have a tapering jig for my table saw I opted to use my band saw to execute these cuts. I have my band saw set up with a half inch blade and it surprisingly cuts pretty clean through this plywood. If you stay tight to the line the taper comes out looking really good.
To prevent chipping of the thin birch veneer on this plywood I used my random orbit sander to ease over all the sharp edges.
With most of the woodworking finished I start assembling the trays using glue and 1” brad nails. There won’t be a lot of pressure being exerted on these trays so screws would have been overkill.
The supports for each tray are made out of dimensional 2×4 lumber that has been kiln dried. I cut each support to a rough size first using my miter saw.
I then cut each one to length at my table saw using my cross-cut sled to ensure their accuracy in both length and squareness.
To attach the supports to the trays I first square each one individually to the bottom tray. Using a clamp to hold it in place I first tack the support onto the tray using 1” brad nails then permanently secure it using 1 ¼” interior construction 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. Before attaching them however I decided to add some reinforcement blocks to the areas the castors will be attached, just to provide some extra support.
I’m using 2” castor wheels and I attach them using 1” pocket hole screws. You can use any screws you like but these were the ones I personally had on hand and they worked great. The castors on the backside of the cart are locking swivel castors so that when the compressor is charging the cart doesn’t move across the floor unintentionally.
To give the compressor hose a place to be stored on the cart I found some large hooks at the home store. These hooks had a large enough radius to accept the entire hose with some room to spare.
That completes this project. All that’s left to do now is see how everything fits. This cart was a great solution to the problems I had with the storage of this air compressor and has already come in handy numerous times in my work shop. This project has quickly become one of my most watched video tutorials on YouTube and I would like to invite you to view all the other content that I have released since this tutorial. You can easily navigate to my channel by clicking on the YouTube icon located at the top right corner of this web page. Thank you for reading and watching this tutorial and any other content you may have seen.