Upcycling. Lets Build Small mobile work table. Part 2

Well, not everything always goes the way we planned, and this so-called “small mobile work table” project wasn’t an exception.
16 years of service took their toll on the cart.
To make a long story short, cart wheels on two legs ended up broken.
And I have to figure out what to do next.

Ideas and Reality

In the beginning the idea was to make storage space under the table top, big enough for a deep drawer.
Now with wheels broken I have to change the height of that space to keep overall height of table in reasonable aisles, while replacing small wheels with bigger wheels and brackets to hold them.

So, time to say ‘good bye’ to spacious drawer and say ‘hello’ to useful shelf. Time to cut.
There was a snowstorm few days ago, and cutting outside as I usually do is not an option.
I have to find a place inside to get messy, and little space by front door is a perfect spot for it.

Move it, set it, mark it. Get ready to cut.
Here is when 36″ clamps from Harbor Freight comes handy. You can get them for as little as $5-6 at any time using 20% off HF coupon. Just google it.
Secure guide with clamps, and slowly cut extra plywood off sides around the shelf using Ryobi P506 5 1/2 cordless saw with Freud D0536X Diablo 5-3/8-Inch Blade.

Wood and Metal

Next is a time to figure out how to put together wood top and metal shelf.
At the beginning I was thinking about standard way to do it – few pieces of wood glued and nailed on each side of the bottom part of top and 4 holes drilled to keep legs at place. But I want to do something different.
Plywood leftovers, old hole saw, drill press, Freud FB-005 3/4-Inch Forstner Drill Bit – and in five minutes I have 4 nice looking round brackets.

My two cents about the process of cutting out round pieces with a hole saw – do not rush.
Rather than push it, take it easy and slowly. Do not try to force your drill, instead play back and forward and let it take care of cutting.
If you have nice straight hole saw you better cut your wood from both sides in order to keep it smooth and without chips at the edges.
My no-name hole saw is a cheap and little bit bent so drilling from both sides wasn’t an option.
It took me longer to do it from one side but as a result it came out really nice.

Next step is sanding.
Easiest way to sand discs is to make them spin.
Piece of ply leftover, one screw and sanding cylinder on drill press.
Slowly rotate discs, do not push it, do not rush it.
It may take longer than using regular table top sander, but I don’t have one.
And it’s much faster than trying to do it by hands.
10 more minutes and I had nice smooth sides.
That is it.

Making donuts

Then comes a time of Freud FB-005 3/4-Inch Forstner Drill Bit .
And I am about to make donuts.
While holding ply disc at the place, slowly drill a 3/4″ hole at the center of each of the four discs.
Same 2 cents as before – do not force it, do not rush it.
Finishing top and bottom with orbital sander #200 sandpaper.


Small mobile work table. Assembling. First try.

Seems like metal shelf became a little bent over the years, so there is no easy “measure it – mount it” way to place and center plywood donuts.
Therefore the easiest way I think of is turning table top upside down, mounting donuts on legs and then positioning it. In this case you can see end result before you start gluing and drilling.
When donuts are positioned correctly, cover bottom side of donuts with wood glue and secure it with few 1 1/4 brad nails.
Let it dry a bit, pull out metal cart, pre-drill holes and screw donuts down to places with 1 1/4″ screws.
Ply shelf and donuts are ready for sanding and finishing.

Now I have to wait for good weather… (fingers crossed)

What do you think?
If you like it, don’t be shy to drop comment or two, or just share it – this would be very helpful for us!

Leave a Reply

Your email address will not be published. Required fields are marked *