Flip top tool cart build. - Page 2 - Woodworking Talk - Woodworkers Forum

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post #21 of 56 Old 11-03-2012, 09:22 PM Thread Starter
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Hey I am still alive and got to actually put in some shop time today. The hurricane, and my mom going home after a four month visit, slowed me down a bit. But hey it has only been two weeks since I started this project compared to my unfinished, six month jewelry box, this cart should be wrapped up shortly.

Today I sanded all the case pieces, drilled the screw holes and glued and screwed it together. I then finished gluing the cleats and kick plate in place and put on the casters. I thought I had four, but only could find three. Looks like a HF run tomorrow. I hope they have one in stock. Things are going well.

On a previous day I cut the slots for the eye bolts and used a hand plane to chamfer the edges. I had a router bit, but have the wrong base plate for it, so I went old school. My chamfers are not perfect, but they are hand crafted, haha.

Next step will be to mill some rough poplar for the top filler pieces and build the top. Today was my first of five days off, so I hope to finish this baby.



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post #22 of 56 Old 11-03-2012, 09:24 PM Thread Starter
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TP I really have not used the Craftsman DP enough to have an opinion. I got it for $75 on CL, so I really can't complain. It works well enough.
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post #23 of 56 Old 11-03-2012, 09:39 PM
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your cart looks great. I need to make something like this for my planer. tplociniak I have the same craftsman DP and it works relay well. I have had it for a year and a half with no problems. Sears has discontinued it unfortunately.

Lighten up . It's just the internet.
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post #24 of 56 Old 11-04-2012, 07:32 PM Thread Starter
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Moving right along. Milled some rough poplar to make the top spacers. Silly me was not thinking and only milled enough to make the front and back spacers and not the sides. Duh! So I had to mill one more board. Wouldn't be a big deal if I didn't have to constantly switch plugs and dust collector hose between machines. But it really was not that bad. Was loving my Delta 8" Jointer and Dewalt 734 Planer. Also noticed that the only time I got snipe on the planer was when I didn't lock the head down. You learn something every day.

After cutting all the poplar spacers to size, I had to find a way to notch the spaces for the eye bolt latches. It said to use the table saw, but I have no tenoning jig and was nervous about free handing it. I tried to use the BS, but it did not work right. I then decided to try the TS. I put the 1/4" dado set on and a taller fence and went for it. Probably not the best, or safest way to do it, but it got done. I will make a tenoning jig before trying that again freehand.

Got the spacers glued to one side of the top and waiting for it to dry a bit and then I will glue the other side on. She is coming along nicely.


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post #25 of 56 Old 11-04-2012, 07:36 PM
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Sorry I'm late to the show Paul.
It's looking good so far. It's nice to have your tools easily accessible. I need to make a couple of them myself, so ill be watching you.

When it's rustic......it's rustic
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post #26 of 56 Old 11-04-2012, 09:07 PM
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Quote:
Originally Posted by Paul W Gillespie

After cutting all the poplar spacers to size, I had to find a way to notch the spaces for the eye bolt latches. It said to use the table saw, but I have no tenoning jig and was nervous about free handing it. I tried to use the BS, but it did not work right. I then decided to try the TS. I put the 1/4" dado set on and a taller fence and went for it. Probably not the best, or safest way to do it, but it got done. I will make a tenoning jig before trying that again freehand.
I laid out the length of the slot, drilled the appropriate diameter hole at the end of each slot and finished up with my jig saw and a file.

Looking good Paul. My flip tops may be the most useful shop projects I've done so far.

Jeff

Edit: Sorry Paul I just realized you were talking about notching the top spacers not the cart sides. ;/

I used a tenoning jig. I had to build one to complete that part of the flip top project. Funny how one thing leads to another.

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Last edited by jharris2; 11-04-2012 at 09:11 PM.
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post #27 of 56 Old 11-04-2012, 10:38 PM Thread Starter
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Well the top is glued. I drilled the holes and installed the eye bolts. Then drilled the hole in the top for the 1/2" metal bar I used for the pivot. That is where I needed Thor's hammer to get it through the top. My holes must be off slightly or the rod bent a bit, or both. I had to cut a couple wholes to guide it. I got it through though and it pivots. Not too bad, almost smooth. I might need an adjustment here and there.

I also needed to trim the whole top a bit to get it to fit. I didn't use my ZCI and got some chip out on one side. I may put some trim along the side to hide it.

So I may put a few coats of poly on it for protection and need to drill the bar for some cotter pins. Should have done it before. Then I put the tools on it. Stay tuned.

I am also going to build some storage bins on the sides for accessories.



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post #28 of 56 Old 11-05-2012, 05:27 AM
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Looking good Paul.
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post #29 of 56 Old 11-06-2012, 06:14 PM Thread Starter
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Finished sanding the top and put a first coat of Minwax Fast Dry Gloss Poly on it. I am not the best finisher. A few runs, drips and some saw dust on her, but OK for a shop cart. I would usually stop now. I think my DP Cart only has one coat of poly on it. I know you should put more on and if it were a project for the home, I would and will for this cart, as practice. So I guess I will need to give a light sanding with something like 220 or higher, right? Then some more poly.




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post #30 of 56 Old 11-06-2012, 10:07 PM
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Yeah, thats how I do it. Real light scuff sanding with 220, then another coat like you said. I usually do 3 coats, but thats me. Looking great man.
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post #31 of 56 Old 11-06-2012, 11:21 PM
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Paul, if you typically stop at 85-90%, you got me beat by more that 50% right now on this. I built the same one, same plans, and never put a finish on it -- heck, I don't think I even sanded any part of it. Well, not on purpose (palm random orbital sanders don't stop just because you flip the switch off...). Looks good!

Turning good wood into designer firewood on a daily basis.....

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post #32 of 56 Old 11-07-2012, 12:04 AM
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I think I may build one of these also. My local discount wood seller often has pre finished 11 ply birch for 40 ish /sheet.

happily making big boards into littler boards
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post #33 of 56 Old 11-07-2012, 01:30 AM Thread Starter
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Schnitz, I am trying to be a better woodworker and kicking it up a notch. I may draw the 95% done and I am finished line at finishing the finish. I need the practice for bigger, better projects. I still also need to drill some holes in the metal bar for cotter pins and the plastic knobs are also missing, so I could leave them off to keep my unfinished record going.
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post #34 of 56 Old 11-07-2012, 01:32 AM Thread Starter
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DST I wish I could find 11 ply boards for 40ish around me. This cart is an easy build. It is only my fourth project and I finished it with part time work, in little over three weeks. Well almost finished it.
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post #35 of 56 Old 11-07-2012, 12:02 PM
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Looking good.
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post #36 of 56 Old 11-07-2012, 01:31 PM
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I started with the same set of plans but deviated just a little. Open frame using 2x4 stud lumber was much cheaper than double plywood. I did use plywood for the top. Double layer of 3/4 BC plywood framed with 2x4 material. Dados down the center of the two pieces of plywood gave a hole completely through the top so I used 1/2" black iron pipe for the top to pivot around. Turn buckle locking mechanism also worked pretty well. No rods sticking out around the sides. They did need a bit of adjusting by gluing tapered shims to the bottom side. I had just a little rocking in the top at first.
Drawer pulls through from both sides. I have the OSS on one side and the bench grinder and the Worksharp on the other. I had interference in the mounting holes trying to mount them so the front was always the front of the stand, hence, the pull through drawer.
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post #37 of 56 Old 11-07-2012, 01:36 PM Thread Starter
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Very good John. Great idea about the pipe and the drawer at the bottom. I had planned on putting a drawer in the bottom of mine and even cut a piece of plywood for the drawer box top, but didn't measure the height of the cart correctly and had no room for it. I may use the 24"x24" piece of ply for a cross cut sled.
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post #38 of 56 Old 11-09-2012, 05:46 PM
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Paul, I built the very same flip-top cart. Yours look very nice!! Mine is stained about 90% with some old minwax stain that I had laying around. I ran out before I could finish it. I have my miter saw on one side and I used to have an old drill press on the other side. It was a God send. To be able to flip the top to get to each tool. And along with the ability to roll it around my shop made it even better. I built a removable wing, if you will, that gives my material support when I use the miter saw. My old drill press bit the dust a while back and my new-to-me drill press was too big so now I have an old scroll saw where the drill press was. I don't really use the scroll saw but since it was laying on the floor and I was always moving it or walking around it I thought I might as well secure it to the other side time being.

- Bob
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post #39 of 56 Old 11-09-2012, 08:21 PM Thread Starter
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Oh yeah, after being lazy the last couple of days, tonight I sanded the first coat of poly and put on a second coat. I have never sanded poly for a second coat before and when I started I was seeing small scratches with the 220 sandpaper. I started to worry, but followed through. Wiped it all down with a tack cloth, man that was tacky. Even my hands were super tacky afterwards. I then started the second coat and boy was I surprised. It was looking like glass, to me anyway. The first coat seemed to soak in a lot, but this coat really shined. Sure it is still wet, but I was happy at the gloss. We will see what it looks like when dry.

The first coat got a rough feeling when dry, will the second coat stay smooth or will it also rough up? Who knows I may hit it again with another coat. I know it is a shop cart, but it also practice finishing so it may coat it up super glossy.

Pictures to come later.
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post #40 of 56 Old 11-09-2012, 10:00 PM
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Paul, the second may be slightly rough and fuzzy but nowhere near as rough as the first coat. Sounds like things are progressing normally with your finish. It is amazing how differently the first and seconds coats come out. If, by chance, your second coat is slightly rough, only sand it very lightly with fine paper (280-320 or so) and the third coat will be incredible. I use good quality sanding sponges (3M, I think); "x-fine" grit. Avoid the crappy ones that Harbor Freight sells. The grit falls off if you look at them too hard.
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