mobile

hardware
organizer

© 2016 Cruz Bay Publishing, Inc.

Shop
Project

Mobile
Hardware
Organizer
With simple plywood
construction and a
wide range of storage
options, this cart holds a
lot of supplies and
lets you roll them right
to the job at hand.

For most of us, storage seems to be a
perpetual challenge, whether it be in the
house, the garage, or the shop. And in the
case of the shop, a big part of the prob-
lem is the range of items that we have to
store — from large to small. That’s why
I like this hardware organizer. Instead of
a one-size-fits-all approach, it has several
storage options in a number of sizes.
Starting at the top, there’s an assort-
ment of plastic storage bins to keep your
various screws, bolts, nuts, and washers
organized. Below that is a section con-
taining metal trays of varying depths for
larger items like hinges, knobs, or pulls.
Further down are two deep drawers that
are roomy enough to hold things like
drills, routers, or other small power tools.
LONG ITEMS. And for items that are too
long to fit in any of these containers,
there’s a row of vertical storage cub-
bies at the back of the cart — perfect for
things like threaded rod, metal stock,
dowels, or even clamps. So even though
we’re calling it a hardware organizer,
it’s really more than that. And it all fits
in a convenient, compact footprint.

1 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
Construction Overview / OVERALL DIMENSIONS: 27!/8"W x 51"H x 19!#/16"D
Back compartment
Clear covers on is divided up for
bins keep out vertical storage
dust and debris

Upper shelves hold

three sizes of
plastic bins
Slide-out tray
lets you easily
sort hardware

Case is
constructed
out of
Baltic birch
plywood

Metal trays slide

in kerfs in the
support panels
Drawers are Drawers ride
built with tongue on metal
and dado joinery at slides
front and dado joints
at back

Cart rolls smoothly

on heavy-duty
casters, even when
fully loaded

< A pair of drawers at

the bottom of the
cart are deep enough
to store smaller tools.

Metal trays provide >

storage for hardware
items that are too big
or bulky to fit in the
plastic bins above.

2 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 1
4&/8
INNER E
a.
BACK
CASE 12#/8 D
8#/4 B
TOP
1!/8 #/4" ply. 13%/8
23!/2 A
23
3#/8 #/4"
ply.
UPPER !/4
7 DIVIDER
#/4" 31%/8 C
D
44!/2 ply. 8 (rgh.)
FRONT
7 SIDE VIEW SECTION VIEW
15!/8 4!/2 12!/2
A
A b.
6 !/4"-dia. hole, LOWER C
!/4
#/8" deep DIVIDER
29
7 D
CASE 12!/2
#/4" SIDE
ply. A D
LOWER
DIVIDER
12#/8 NOTE: Screw
holes are !/2" ply.
centered FRONT VIEW
on width
of dadoes 17!/2
23!/2
18
c.
!/2" ply.

3 #8 x 1!/2" Fh
4 #/4" !/4
ply. 1#/8 woodscrew D TOP
!/8 w/#8 finish SECTION A
4 CASE VIEW
washer BOTTOM
E 15&/8
8#/4 15 e.
3 NOTE: Inner back
is !/2" Baltic birch E B
TOP VIEW plywood. All other
parts are #/4"
Baltic birch plywood
A
3
NOTE: Dry assemble d. !/2" ply.
case to mark case top
for final width 4 #/4"
#/4" ply. C
ply. !/8
E

E !/4
BACK VIEW
D

It starts with a CASE

D 3
TOP VIEW SIDE SECTION VIEW
A

#/4"
ply. of the nice things about this project
One shorter dimension.) To help you with Figure 1 in the How-To box on the next
is that there’s !/4
nothing too complicated laying out the cuts, you’ll find a ply- page. You’ll notice that to cut the rab-
about
D building it. Most of the parts are wood cutting diagram on page 10. bet along the bottom end of the sides,
plywood, and they’re held together I cut all the parts to overall finished I attached an auxiliary fence to my rip
FRONT E B
primarily
SECTIONwith
VIEW glue and screws. A few size, with the exception of the case top. fence. After cutting all the dadoes, you
dadoes, grooves, and rabbets help keep This piece is left a little wide and then can then bury the dado blade in this
everything aligned during assembly and trimmed to final width to match the auxiliary fence to cut the rabbet along A
add to the overall rigidity. taper of the sides before assembly. the back edge of each side for the back
!/2" ply.
As you can see in the drawing above, DADOES & RABBETS. The case sides have panel that is added later (detail ‘c’).
the case is made up of two sides joined dadoes on their inside faces to hold the HOLES. Once all the joinery is com-C
by a top, a bottom, and two dividers. case top and dividers, as well as some pleted, the next order of business is to
These parts are all cut from 3⁄4" Baltic shelves that are added later. They also drill a number of screw holes. !/4 First, I
birch plywood. You’ll want to pay atten- have rabbets to hold the case back and drilled a series of holes for the screws
D
tion to the grain direction when cutting bottom. To cut these joints, I set up a used to attach the sides to the divid-
out the various parts. (To minimize the dado blade in my table saw to match the ers. These are centeredSIDE on theSECTION
width VIEW
amount of waste, some of the parts are thickness of the plywood. Then I cut the of the dadoes, as shown in detail ‘a’
cut with the grain running along the dadoes as shown in detail ‘a’ above and and the Side View drawing. I also

3 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
drilled some shelf pin holes on the How-To: joinery, Tapers & chamfers
inside face, near the back of each case
side. Again, you can see the locations
for these in the Side View drawing on
1 a. b.
END END
the previous page. VIEW !/8 VIEW
TAPERS. With all of the holes taken care #/4"FRONT
ply. SECTION !/2" ply.
of, it’s time to turn your attention to the A VIEW
tapers on the front edges of the case !/8"!/4 #/4
!/4
chamfer A F A
sides. After fastening the workpieces
NOTE: Attach aux.
together with double-sided tape, I laid fence to rip fence 3!/2
out the taper and made a rough cut
with a jig saw, as shown in Figure 2 in
the How-To box. Then to get a smooth, Case Joinery. To cut the dadoes and rabbets in the case sides, set up a dado
straight taper, I trimmed the cuts with a blade in your table saw to match the thickness of the plywood. After adding
router as detailed on page 9. an auxiliary rip fence, cut the rabbets at the bottom and back edge.
DIVIDERS. The two dividers also have
some joinery and holes to take care of.
For starters, there’s a narrow dado cut
2 3
F
in the lower divider that will hold an
inner back panel (detail ‘e’ on previ- Chamfer
bit
ous page). Then each divider receives a
Tape case
centered groove, as shown in the main sides together
drawing and detail ‘b’ on the previous a. END VIEW
#/8"
chamfer
page. You’ll also need to drill some
screw holes centered in these grooves F !/8"
chamfer
to hold some support panels that are NOTE: Cut to
waste side
added later in the construction process. of layout line
ASSEMBLY. At this point, you’re ready
for some initial assembly. I started by Creating the Tapers. With the two Caster Plates. To ease the sharp
joining the case sides to the bottom and side panels taped together, rough out edges of the caster plates, I used two
dividers. Just make sure that the front the taper with a jig saw. different sizes of chamfers.
edges are flush with the front edges of
the case sides. (Leave the case top out
for now.) Since these screws will be vis- a. !/8
ible, I used finish washers under them. #/8"
CASTER FRONT SECTION
chamfer VIEW
With the case partially assembled, PLATE
F !/8" #/4
you can now measure the opening for chamfer F
the inner back and cut it to size from
1⁄ " Baltic birch plywood. Like the case 4"-dia.
2 3!/2
caster
sides, the inner back has a series of F
grooves and numerous screw holes. 19 b. !/2
You can see the details in the Back View NOTE: Caster
plates are glued
drawing on the previous page. up from two F
Final assembly. To complete the case layers of #/4"-thick
hardwood
assembly, glue the inner back into the
dado in the lower divider and screw SIDE
%/16" x 1!/2" #8 x 2" Fh
it to the upper divider. Then slip the lag screw woodscrew
SECTION
and washer VIEW
case top in place and mark it for width.
After beveling it to match the taper on
the sides, it can also be installed. As you can see in the drawing above, are chamfered before they’re added to
the casters are attached to a pair of the case. Details ‘a’ and ‘b’ show where
CASTER PLATES caster plates that are screwed to the they’re positioned.
In order too make it easier to move the bottom of the case. Once the plates are in place on the bot-
organizer around while working on Each caster plate is glued up from two tom of the case, the casters are attached
the rest of the components, I decided to layers of hardwood. Then to ease the with lag screws and washers. Then the
add the casters to the case at this point. sharp edges, the top and bottom faces case can be set on the floor.

4 END WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
VIEW
 6 6
holes all
the way
through
dividers

FRONT VIEW
#8 x 1!/4"

Filling the SPACE

Fh woodscrew VERTICAL
G
DIVIDER a. %/8

One of the things that makes this hard- G

ware organizer different than most other %/8

7
storage carts is the rear storage area. The 31#/8
cavity at the back of the organizer is
divided up into vertical compartments
for storing metal stock or any other
long, skinny items. Adjustable shelves NOTE: Drill
shelf pin
prevent shorter items from dropping holes all 6
down too far into the compartments. the way
through
And an easily removeable back panel dividers
offers quick access to the shelves if you
FRONT VIEW
want to raise or lower them.
To partition the space, I began by 44!/2
making the four vertical dividers. Like 23!/2
4!/2
so many of the other pieces of this cart, 4%/8
these are just cut to size from 3⁄4" ply-
wood. Then they’re drilled for shelf pins. 3&/8
H
To save time, I stacked the dividers in REAR
pairs while drilling the holes, as you can SHELF
see in Figure 1 in the box below. This also NOTE: Vertical dividers
are #/4" Baltic birch plywood.
helps to ensure that the holes line up. Shelves and back are
!/2" Baltic birch plywood CASE
The vertical dividers are sim- BACK
ply glued and screwed in place I
d.
SIDE b. TOP c. G SIDE
VIEW through the lower divider and VIEW H
VIEW
I
inner back of the case (detail ‘b’).
H The grooves that you cut earlier Brass
G H H turn-
in the inner back help to keep the !/4 2 button
!/4" dividers aligned vertically while !/4"
helf driving the screws. H shelf
pin !/16 pin
SHELVES & BACK. With the vertical
dividers in place, you can cut
some small shelves to fit between them. back. This is nothing more than a piece the adjustable shelves, it’s held in place
These rest on shelf pins, as you can of 1⁄2" plywood that’s cut to fit between with brass turnbuttons, as shown in the
see in detail ‘c.’ Then to complete the the rabbets in the case sides. In order to drawing above and detail ‘d.’
compartment, all that’s left is to add a make it easily removeable for access to
TRAY SUPPORT Panels

How-To: SHELF PIN HoleS & Bin guides With the vertical storage compartment
completed, you can turn your attention
to the front of the case, specifically,
G
the
SIDE
1 2 middle opening. This opening holds
two banks of metal trays. Since the trays
VIEW

Aux. are purchased, all you have

H to make areH
fence
a. END some panels to support them. The !/4 trays
VIEW simply ride in saw kerfs cut in the face !/4"
shelf
G a. END VIEW of the the support panels.
pin
!/4" brad- Tilt The tray support panels start off as
point bit G Miter ends blade O P Q four identically sized pieces of 1⁄2" ply-
of guides 20°
to length wood. Using a standard kerf saw blade,
%/8
cut a series of kerfs on the face of each
panel, as shown in detail ‘a’ on the next
Shelf Pin Holes. To speed up the Bevel to Length. When beveling page. The spacing of the kerfs allows
process, I drilled the shelf pin holes the ends of the guides, it’s a good you to mix and match different depths
through two dividers at once. idea to sneak up on the final length. of metal trays to suit your needs, or rear-
range them down the road.

5 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 TRAY
#8 x 1!/4" Fh SUPPORT
The two middle support panels are woodscrew PANEL
glued together back to back and then SIDE J
SECTION NOTE: Tray
installed in the grooves in the case divid- VIEW support panels
#/4 are !/2" Baltic
20°
ers. The outer support panels are just bevel birch plywood
glued to the sides of the case. However, #/4
N

they have to be trimmed down before NOTE: Refer #/4" ply.

they will fit in the opening. When you to page 11
for source of
do this, just make sure to trim equal metal trays
J
amounts from both the top and bottom
edges of the supports so that all the kerfs
line up after installation. a.
15%/8

BIN SHELVES !/2 12!/2

The upper section of the organizer holds !/8
1!/8
three sizes of plastic storage bins. The !/8 NOTE: Glue two
NOTE: !/8" kerfs inner panels
bins rest on shelves that feature hard- back to back
!/4 1!/8 are spaced
board guides to keep them positioned. 1!/8" apart before installing
J in case
Clear plastic covers on the bins help FRONT
keep out dust and debris but still allow VIEW NOTE: Trim !/4" off each
you to see what’s inside. end of both outside
support panels
If you take a look at the lower draw- before installation
ing at right, you’ll see that the three bin
shelves are different widths. I started by
cutting the blanks for these shelves to NOTE: Bin shelves SMALL BIN
are #/4" Baltic GUIDE BIN
size. The front edge of each shelf is bev- birch plywood. Bin guides O N
STOP
are !/4" hardboard. 23
eled to match the angle of the case sides. Bin stops are #/4"-thick
The next step is to cut a row of dadoes hardwood
in the top face of each shelf. You’ll find SMALL BIN K
SHELF
the spacing of the dadoes in detail ‘b’ 1
NOTE: Refer to
below. These will hold the hardboard page 67 for sources
4(/16
guides that are added later. of plastic bins
and lids
After cutting the dadoes, I added a 23!/2
L
bin stop to each shelf. This is nothing MEDIUM BIN
but a narrow strip of hardwood that’s SHELF 5!/2
6(/16
glued along the back edge of each shelf. P N
It helps to stiffen the shelf and prevents MEDIUM BIN
GUIDE
the plastic bins from being pushed in too 7!/2
far. One thing to note when making the
stops is that they’re a little bit shorter
than the shelves and centered on the
a. SIDE
length. This allows the shelves to slide 10&/16 N SECTION
in the dadoes in the case sides. M VIEW #/4
LARGE BIN 20°
GUIDES. The last parts to make are the bevel
SHELF
11#/8 N
bin guides. As I mentioned before, Q #/4
these are just strips of hardboard that LARGE BIN #/4" ply.
GUIDE
are mitered on one end to match the
bevel on the shelves (Figure 2 on pre-
vious page). After cutting them to final
length, you can glue them into the b.
dadoes in the shelves.
ASSEMBLY. When the guides are in place,
M
the shelves can be added to the case.
4!!/16 4#/8 !/4
I applied a little glue to the front of
each dado in the case sides and slid the !/4 FRONT VIEW
shelves into place so that the front edges
were flush with the edges of the sides.

6 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 NOTE: Drawer fronts, backs,
and sides are !/2" Baltic birch a.
plywood. False fronts are
#/4"-thick hardwood. Bottoms
are !/4" hardboard R
1
16 !/2
DRAWER R
BACK !/4
DRAWER
S FRONT TOP
R SECTION S
5 VIEW
T T
DRAWER
BOTTOM !/4 !/4
(14!/2" x 21!/2")
21!/2
5!!/16
U

16" full-extension
drawer slide 22&/8
5 d. !/4
Pull
S
handle
DRAWER #/4
1 b. R
SIDE FALSE U #8 x 1!/4" Ph woodscrew
!/2 FRONT FRONT
U SECTION
!/4"
!/4 NOTE: False fronts c. chamfer
VIEW
are flush with bottoms
of drawer fronts and SIDE
N S TOP centered on width VIEW
!/4 R U
SECTION
VIEW U
T 2(/16
S !/16
!/4 !/4

U Completing the ORGANIZER

At this point, there are only a couple of
items left to take care of. A pair of draw-
ers fill in the large opening at the bottom
of the organizer. And a slide-out sorting
tray completes the organizer.
DRAWERS. The two drawers are identi-
cal. They’re made out of plywood with
hardboard bottoms and a solid-wood
false front. They ride on full-extension
metal drawer slides.
To make the drawers, I started by cut-
ting out the drawer fronts, backs, and
sides from 1⁄2" plywood. As you can see
in detail ‘a,’ the sides are connected to
the drawer fronts by means of a tongue
and dado joint. Figures 1 and 2 in the
box below will give the specifics on cut-
ting the joinery. The drawer back, how-
ever, simply fits in full-width dadoes
cut on the inside face of the drawer
sides — no tongue is required (detail
‘a’). There’s also a groove cut on all four
drawer pieces for the bottom panel, as
shown in detail ‘d’ above.
ASSEMBLY. After drilling some screw
holes in the drawer fronts to attach
the false fronts and cutting the drawer
bottoms to size, you’re ready to assem-
ble the drawers. Figure 3 shows the
sequence I used. Check to make sure

How-To: Make the Drawers 3

1 2 Slide bottom
into drawer
!/4" dado and then add
blade Aux. rip remaining
S fence R side
R
T
a. END VIEW a. END
VIEW R R
!/4 !/4 !/4
!/4
Cut tongues U
!/4 S S
on ends of
drawer front
only
TOP
SECTION
VIEW
Dado. To join the drawer sides to the Matching Tongue. Cutting a tongue Assembly. Assemble the drawers by
front, start by cutting a dado at one on each end of the drawer front to fit gluing the front and back into one side.
end of the drawer sides. the dadoes completes the joint. Then add the bottom and remaining side.

7 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
 8 Pull
NOTE: Tray bottom is !/2" BACK handle
Baltic birch plywood. EDGING
Tray edging is W
#/8"-thick hardwood

12
6#/8
X #8 x #/4"
22&/8 Ph woodscrew
11!/4
TRAY
BOTTOM b.
22!/8 V FRONT
Pull a. TOP VIEW SECTION VIEW
handle

W W
X
SIDE 1!/16
1!/16 X
#8 x #/4" W EDGING V
Ph woodscrew FRONT V X
EDGING

that everything is square as you apply
the clamps. Once the clamps come off,
you’re ready to install the drawers.
Detail ‘d’ on the previous page will
help you position the drawer slides.
False fronts. To complete the drawers,
I added hardwood false fronts. A large
chamfer softens the inside upper edge,
as shown in detail ‘c.’ Then the false
fronts are screwed in place, taking care
to position them for even gaps around
both drawers. Finally, pulls are screwed
to the front of the drawers.
SORting tray
There’s one final detail to wrap up in
order to complete the hardware orga-
nizer. Below the shelves for the plastic
storage bins is a slide-out tray. This shal-
low tray is handy for sorting hardware
or as a place to set your tools while
working on a project.
As you can see in the drawing above,
the sorting tray is sized to fit in the nar-
row opening between the plastic bins
and the metal trays. It just sits directly
on the upper divider.
Fortunately, the sorting tray couldn’t
be any simpler. It’s a piece of 1⁄2" ply-
wood surrounded by some hardwood
edging. Like the drawers, a handle com-
pletes the tray. And while I was at it, I
added handles to the sides of the cart to
make it easier to move around the shop.
After applying a finish to the project
(refer to page 11 for details), you can
start loading it up with all your hard-
ware, tools, and supplies. I’m betting
you’ll be pleasantly surprised at just
how much stuff it can hold.

Materials, Supplies & Cutting Diagram

A Case Sides (2) 3⁄ ply. - 18 x 441⁄
4 2 Q Lg. Bin Guides (4) 1⁄4 hdbd. - 3⁄4 x 11 rgh. • (20) 1⁄4" Nickel Shelf Pins
B Case Top (1) 3 ⁄4 ply. - 8 (rgh) x 23 ⁄2 1 R Drawer Fronts/Backs (4) 1⁄2 ply. - 5 x 211⁄2 • (6) Brass Turnbuttons
C Upper Divider (1) 3 1
⁄4 ply. - 23 ⁄2 x 12 ⁄2 1 S Drawer Sides (4) 1⁄ ply. - 5 x 16
2 • (4) 1" Metal Trays
D 3 1
Lwr. Div./Bottom (2) ⁄4 ply. x 23 ⁄2 x 17 ⁄2 1 T Drwr. Bttms. (2) ⁄4 hdbd. - 141⁄2 x 211⁄2
1 • (4) 2" Metal Trays
E Inner Back (1) 1⁄ ply. - 23 x 315⁄
2 8 U False Fronts (2) 3⁄ x 511⁄ - 227⁄
4 16 8 • (4) 3" Metal Trays
F Caster Plates (2) 1 1
1 ⁄2 x 3 ⁄2 - 19 V Tray Bottom (1) 1 ⁄2 ply. - 111⁄4 x 221⁄8 • (5) 53⁄8" x 41⁄8" - 3" Plastic Bins
G Vertical Dividers (4) 3⁄4 ply. - 45⁄8 x 313⁄8 W Tray Fr./Back Edging (2) 3⁄8 x 11⁄16 - 227⁄8 • (5) 73⁄8" x 41⁄8" - 3" Plastic Bins
H Rear Shelves (5) 3 1 7
⁄4 ply. - 4 ⁄2 x 3 ⁄8 X Tray Side Edging (2) 3⁄ x 11⁄ - 12
8 16 • (5) 107⁄8" x 41⁄8" - 4" Plastic Bins
I Case Back (1) 1 1
⁄2 ply. - 23 ⁄2 x 44 ⁄2 1 • (5) 53⁄8" x 41⁄8" - 3" Bin Lids
J Tray Supports (4) 1⁄2 ply. - 121⁄2 x 155⁄8 • (28) #8 x 11⁄4" Fh Woodscrews • (5) 73⁄8" x 41⁄8" - 3" Bin Lids
K Sm. Bin Shelf (1) 3 1
⁄4 ply. - 5 ⁄2 x 23 ⁄21 • (20) #8 x 11⁄2" Fh Woodscrews • (5) 107⁄8" x 41⁄8" - 4" Bin Lids
L Med. Bin Shelf (1) 3 1
⁄4 ply. - 7 ⁄2 x 23 ⁄21 • (6) #8 x 2" Fh Woodscrews • (2 pr.) 16" Full-Extension Drawer Slides
#/4"x 6" - 84" Hard Maple (3.5 Bd. Ft.)
M Lg. Bin Shelf (1) 3⁄ ply. - 113⁄ x 231⁄
4 8 2 • (20) #8 Finish Washers • (5) Pull Handles
F F F F
N Bin Stops (3) 3⁄ x 1 - 23
4 • (16) 5⁄16" x 11⁄2" Lag Screws • (8) #8 x 11⁄4" Ph Woodscrews
N X W
O Sm. Bin Guides (4) 1⁄4 hdbd. - 3⁄4 x 5 rgh. • (16) 5⁄16" Washers • (2) #8 x 3⁄4" Ph Woodscrews
N
P 1 3
Med. Bin Guides (4) ⁄4 hdbd. - ⁄4 x 7 rgh. • (4) 4"-dia. Locking Swivel Casters NOTE: Parts X and W are planed to #/8"
#/4"x 6" - 48" Hard Maple (2.0 Bd. Ft.)
ALSO NEEDED:
#/4"x 6" - 84" Hard Maple (3.5 Bd. Ft.) One and one-half sheets of #/4" Baltic birch
U U
plywood, one and one-half sheets of !/2"
F F F F Baltic birch plywood, and one 24"x 48"
N X W sheet of !/4" hardboard
N
NOTE: Parts X and W are planed to #/8"
#/4"x 6" - 48" Hard Maple (2.0 Bd. Ft.)
ALSO NEEDED:
U U One and one-half sheets of #/4" Baltic birch
plywood, one and one-half sheets of !/2"
Baltic birch plywood, and one 24"x 48"
sheet of !/4" hardboard

8 WoodsmithPlans.com WS22526 ©2016 Cruz Bay Publishing, Inc. All Rights Reserved.
Shop Notes
Tapers on Large Pieces
Cutting tapers on large panels like the 1
sides of the hardware cart can be a chal- Case
side
lenge. The workpieces are too big and Clamp Use pattern bit
hardboard to trim taper
awkward to handle comfortably on the straightedge flush with
table saw. So instead, I roughed out the along straightedge
layout line
tapers with a jig saw and then cleaned a.
up the edges with a straightedge tem-
plate and a pattern bit in my router, as
you can see in Figure 1.
Because the cutting length of my
Tape case
pattern bit is only 1", I had to trim the sides together Lower bit
with double-sided to trim
edges in two passes, lowering the bit in tape remaining
between passes (details ‘a’ and ‘b’). waste
b.

#6 x !/2" Fh
woodscrew
BACK

SIDE
!/16" aluminum angle,
%/8" x %/8" - 12!/8"
Shop-Built Trays SIDE
While the metal trays originally used
aren’t made any longer, you can make
BOTTOM
trays pretty easily. The three sizes &/8"-dia. NOTE: Bottom is !/8"
plywood. All other parts
shown here offer a lot of combinations. (/16
are #/8"-thick hardwood
FRONT
The joinery is the same tongue and !/16
dado used on the larger drawers — a. TOP SECTION VIEW
with a twist. The orientation is turned !/4 Side
!/8
90° so that the exposed grooves are on for a pull. Second, the sides have a rab-
Back
the sides rather than the front and back bet to accept a piece of aluminum angle.
(drawings below). One flange nests in the rabbet. The other #/16
There are two other details to note. flange slides into kerfs cut into the tray Side

First, the tray fronts have a hole used support panels.

b. c.
!/4
!/8 Side
(/16 Bottom
4#/4 Large Drawer Side !/8
Large Drawer Front !/16
!/4
Side FRONT
10&/16 12!/8 SECTION VIEW

d. TOP VIEW
1

3!/2 Medium Drawer Side

Medium Drawer Front !/8 !/4 Front
!/4 Bottom
!/8 Side

Bottom
!/8
!/4
!/4 1
Small 2!/4 #/16 Small Drawer Side FRONT
Drawer Front SECTION VIEW

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Hardware Organizer
Plywood & Hardboard Cutting Diagram
A Case Sides (2) 3⁄ ply. - 18 x 441⁄
4 2
B Case Top (1) 3 ⁄4 ply. - 8 (rgh) x 231⁄2
C Upper Divider (1) 3⁄4 ply. - 231⁄2 x 121⁄2
D Lwr. Div./Bottom (2) 3⁄4 ply. x 231⁄2 x 171⁄2
Mobile
I Case Back (1) 1⁄ ply. - 231⁄ x 441⁄
2 2 2 Q Lg. Bin Guides (4) 1⁄4 hdbd. - 3⁄4 x 11 rgh.
J Tray Supports (4) ⁄2 ply. - 121⁄2 x 155⁄8
1 R Drawer Fronts/Backs (4) 1⁄2 ply. - 5 x 211⁄2
K Sm. Bin Shelf (1) 3⁄ ply. - 51⁄ x 231⁄
4 2 2 S Drawer Sides (4) 1⁄ ply. - 5 x 16
2
L Med. Bin Shelf (1) 3⁄4 ply. - 71⁄2 x 231⁄2 T Drwr. Bttms. (2) ⁄4 hdbd. - 141⁄2 x 211⁄2
1

E Inner Back (1) 1⁄ ply. - 23 x 315⁄

2 8 M Lg. Bin Shelf (1) 3⁄ ply. - 113⁄ x 231⁄
4 8 2 V Tray Bottom (1) 1⁄ ply. - 111⁄ x 221⁄
2 4 8
G Vertical Dividers (4) ⁄4 ply. - 45⁄8 x 313⁄8
3 O Sm. Bin Guides (4) ⁄4 hdbd. - 3⁄4 x 5 rgh.
1

H Rear Shelves (5) 3⁄ ply. - 41⁄ x 37⁄

4 2 8 P Med. Bin Guides (4) 1⁄4 hdbd. - 3⁄4 x 7 rgh.

#/4" Baltic Birch Plywood - 60" x 60" #/4" Baltic Birch Plywood - 30" x 60"

Grain
direction !/4" Hardboard - 24" x 48"
B

G G G G
C T

Grain
direction
D T
A A O
P

K L M P
Q
D

!/2" Baltic Birch Plywood - 60" x 60" !/2" Baltic Birch Plywood - 30" x 60"

J J Grain Note: Design option

J J
direction
drawers not included
tt

in cutting diagram

H H H H H

S S S S
Grain
direction
I

R R R R V

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 MAIL Project Sources
ORDER • Essentra Components
SOURCES Utility Handle . . . . . . . . DUH-50
Lee Valley • Lee Valley
800-871-8158 1" Metal Trays . . . . . . . 05K98.10
leevalley.com 2" Metal Trays . . . . . . . 05K98.20
Rockler
3" Metal Trays . . . . . . . 05K98.30
800-279-4441 4" Swivel Casters . . . . . 00K21.41
rockler.com 16" Drawer Slides . . . . 02K42.16
• Rockler
U.S. Plastics
800-537-9724
#8 Finish Washers . . . . . . . 49587
usplastics.com Brass Turnbuttons . . . . . . . 27912
Shelf Supports . . . . . . . . . . 22773
• U.S. Plastics
53⁄8" Akro Bins . . . . . . . . . . 52041
73⁄8" Akro Bins . . . . . . . . . . 52042
107⁄8" Akro Bins . . . . . . . . . 52266
53⁄8" Akro Lids. . . . . . . . . . . 54911
73⁄8" Akro Lids . . . . . . . . . . 54912
107⁄8" Akro Lids . . . . . . . . . 54913
53⁄8" Akro Dividers. . . . . . . 52111
73⁄8" Akro Dividers. . . . . . . 52112

The hardware cart was finished

with two coats of spray lacquer.
Manufacturers and retailers will
periodically redesign or discontinue
some of their items. So you’ll want
to gather all the hardware, supplies,
and tools you need before you get
started. It’s easy to adjust dimen-
sions or drill different-sized holes
to suit your hardware.

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