Build an Air Compressor Cart – 07

Prior to building this project my air compressor sat in a bin that it was too large to fit in. The pressure the air compressor exerted on the bins lid and sides caused it to slowly fracture at various points. Another issue with storing my air compressor the way it was being stored was that it wasn’t very mobile. 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! Read on to see how I built it.

Mobile Cart Plans



crosscutting plywood to size

This entire project is made from a single piece of half inch Birch plywood purchased from a local supplier. Since I don’t need the entire sheet 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.


Sizing plywood using my table saw

To further reduce the sheet of plywood and rough out the individual pieces I used my table saw. These pieces will make up the sides of each tray.


Sizing plywood using my table saw and crosscut sled

Finally, I reduce the pieces of this cart using my table saw cross-cut sled. This ensures that everything is square and identical in length.


Taping tray parts together to cut them simultaneously

Both the lower and upper trays of this cart are tapered. Since the tapers are 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.


cutting tray parts using my band saw

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.


Sanding tray parts with my random orbit palm sander

To prevent chipping of the thin birch veneer on this plywood I used my random orbit sander to ease over all the sharp edges.


Adding glue to tray parts and assembling with brad nailer

Adding glue to tray parts and assembling with brad nailer

Adding glue to tray parts and assembling with brad nailer

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. I am confident glue woill be plenty strong enough.


Cutting tray supports using my miter saw

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.


Cutting tray supports to size using my crosscut sled on the table saw

Each support piece is cut to length using my crosscut sled. This is overkill, I know…


Assembling cart using glue and screws

Assembling cart using glue and screws

Assembling cart using glue and screws

To attach the supports to the trays I first square each one individually to the bottom tray. I used a brad nailer to hold the trays in place. I secured the trays using 1 1/4″ screws, sinking them through each side of the tray directly into the support. The same procedure is followed for the opposite side of the lower tray and both sides of the upper tray.


Adding pads to the bottom tray in order to attach caster wheels to them

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 decided to add some blocks to the areas the castors will be attached, just to provide some extra support.


Attaching caster wheels with screws

I’m using 2” castor wheels and I attach them using 1” pocket hole screws. Pocket hole screws are great for attaching castors, I highly recommend them. The castors on the backside of the cart are locking swivel castors. Locking swivel castors prevent the compressor from moving across the floor as the compressor charges.


Attaching hose hooks to the support arms

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. You can pick up hooks like this at most home stores in various configurations. I found these is Lowe’s Home Improvement near the perforated pegboard. My guess is that their are plenty of similar products online if these are not suitable for your compressor setup.


Testing the mobile cart on my shop floor

Adding the compressor and accessories to the mobile cart

That completes this project. All that’s left to do now is see how everything fits. This mobile 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. I you would like to see other tutorials 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.

If you would like to see more of my video tutorial projects visit my YouTube Channel and check them out. If your not a YouTube person follow me on Instagram!

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