Mobile Sheet-goods Rack/Cutoff Station

Small-Shop Solutions
50"
Space for
full-width
cutoffs
Fits in the space
alongside your
garage door
18"
Blocks support sheets for
circ-saw breakdown.
Little clearance
needed; tools butt
right alongside.
Mobile Sheet-goods
Rack/Cutoff Station
T
his compact unit packs loads of lumber into only 18" of width.
Casters let you swivel one end to load up sheet goods from
your driveway, then swivel the other to offload sheets into
your shop. The shorts rack side doubles as a simple panel saw, right,
maximizing shop space even more. You can make it in a few hours
from a single sheet of ¾" plywood, one 2×6, and seven 2×4s.
it doubles as a cutoff station
Build up the base
Start by cutting and assembling the 2×4 base with #8×3" flathead
wood screws, as shown in the Exploded View on page 25. Add the 2×6
to the “sheets” side of the base keeping the bottoms of the base
members flush. Cut a 16 1 ⁄2×96" piece of ¾" plywood to serve as the
top of the base. Use a jigsaw to notch the ends and attach it to the
base with #8×2" flathead wood screws.
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DA-00265
©Copyright Meredith Corporation 2011
The protruding ends act as both a clamping surface and a
spacer between the spinning blade and the cutoffs stowed
behind. Use a clamp-on straightedge to guide your saw.
WOOD magazine
July 2011
endS and divider
exploded view
Stack up the rack
Cut the ends and divider to 13×47 ¾".
Then, lay out and cut the angle on
each, where shown in the Ends and
Divider drawing. Set aside the angled
cutoffs for later. Lay out the radius on
the top of each end and the divider and
jigsaw them to shape.
On the divider only, measure from
the top and crosscut the divider down
to 43 ½". Jigsaw the notches for the 2×4
supports where shown, then trace the
cutout locations onto the end pieces for
later reference.
With the base sitting flat on your
workbench, attach the ends to the base,
flush at the bottom edges and snug
against the notches in the base top. (The
ends protrude ½" from the front of the
base to prevent sawing into the horizontal supports when used as a cutoff
station. See photo on page 24.)
Crosscut the four horizontal supports
to fit between the ends. Mark the
location of the divider at 50" on each as
well as on the base top. Install the
horizontal supports and the divider,
positioning it using the marks.
woodmagazine.com
From the angled cutoffs you set aside,
cut 3 ½×4 5 ∕ 8" filler pieces to fit under the
protruding edge of the base top, where
shown.
Install the four support blocks on the
“shorts” side to serve as supports for
breaking down sheet goods. Now load
’er up, tuck ’er away in the corner, and
enjoy the extra space you’ve created.
Cutting Diagram
Project design: Kevin Boyle
Illustrations: Roxanne LeMoine; Lorna Johnson
¾ x 48 x 96" Plywood
For enlargeable versions
of these drawings go to
woodmagazine.com/cutoffstation
1½ x 3½ x 96" Pine (2x4) (5 needed)
1½ x 3½ x 96" Pine (2x4)
1½ x 3½ x 96" Pine (2x4)
1½ x 5½ x 96" Pine (2x6)
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