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Shop Tools – Super Tough DIY Utility Cart

When there is a need that does not really fit with existing products, make your own.  That is where we start with this new, super tough Shop Floor & Utility Cart.  While it is not monumental in design, it does have some great functionality for DIYers, with strength that you will not find elsewhere. It is multi-function, as 3 products in one.

I see shop carts of various types online.  Most of the stouter ones brag 300 lbs or 500 lbs capacity.  I even saw a few at 600 lbs.  At uLine they have some steel carts (dollies) at 1200 lbs.  That is a lot, but the one I just broke was rated at 800 lbs.  Nope, those will not work.  While they would do most things, they are not enough to do the big jobs, like move a trailer frame.

Steel Dolly ExampleThe one in the image is a floor cart (aka Steel Dolly) from uLine at 2000 lbs, which is almost enough, but it has a hard steel top and not so easy to expand for multi-function.  Well, I could put a rubber pad on it.

Also, like many DIYers, I do not have the luxury of a huge shop with tons of open, empty storage space.  When I add a new tool, the purpose and frequency need to justify the space.  So, why not a 3-in-1 tool?  Especially when I can replace an existing (broken) tool with something that will do even more?  That is the genesis of our utility cart for the workshop.

Motivation For A New Utility Cart

The big motivation is a recent job that damaged my existing floor cart.  Obviously, I over-estimated it is ability and the machine I set on it was too heavy.  The machine was easy to haul on the trailer, and easy to lift with the crane, but too much for the cart.  Now the wheels do not turn so well.  – OK, I could just replace the wheels, maybe with some that are a little stronger.  Yet, sometimes I need a much stronger cart, and we are not going to get there with the old one.

Why not build a much stronger one?  So, I did the design.  Actually, 6 designs before settling on this one.

The final motivation is adding an utility cart upper.  It is a great way to make the floor cart more useful, by making it into a utility cart with a worktop.  And, it is like storage in action.

A Super Strong Shop Floor Cart

While the real motivator was damage to the old cart, having a super strong one has been on my mind.  There are several times I was not sure if I should put this or that on one of my existing carts.  I have to admit I have been rather abusive to my floor carts – and this is very likely a contributor to the failure of the old one.  (Aahh, but we can just avoid that conversation …)

Shop Cart Base Equipment Dolly

How much of a floor cart do I need?  What size?  What capacity?

I like a smaller footprint, so something less than 30″ x 24″ seems right for me.  However, I recognize that is not perfect for everyone.  (So, in the plans, there are options to shrink it, or enlarge it.)

It needs high capacity, but it also needs to be low — giving some conflicting limits.  Looking at available casters, I found 600 lbs to 900 lbs each is not unreasonable.  600 * 4 = 2400 lbs, and 900 * 4 = 3600 lbs.  So, that is where we start with this new workshop utility cart.  Pick the casters for the performance.  Higher capacity caster are “harder”, so they make more noise rolling over seams or chips or grit on the floor.  Softer, polymer wrapped wheels, are a little lower capacity but nicer, generally, to use.

For my cart, I chose Caster City Polyurethane, full crown wheels for easy maneuverability and a nice balance of strength and ride.

A Utility Cart Upper

So, the new cart is a stronger, smoother rolling replacement of the old one.  But, what about solving a second concern at the same time?

Utility Shop CartWhen I am working, I like having tools at my fingertips – even when I am not at the workbench and toolbox.  Plus, I often need to move around with the tools from one side of a project to the other – sometimes from one side of the shop to the other.  I gave tried tool belts and they are OK for smaller tools.  I have tried buckets, but they are a hassle.  Mostly I just set the tools down, then walk back and forth carrying tools as I move around the project.

There is the consideration of buying a utility cart, but most of them lack substance, and seem rather wimpy.  However, since I am building a new cart to replace the one I damaged, why not make a utility top as well?  The floor cart can serve as the base for a nice shelf top that is a super strong utility cart!  I like it.

The top does not need to be as strong as the base, because they are for different things.

A Shop Tools Solution!

The result of the design effort is a pretty simple, yet super strong (3000+ lbs capacity) shop floor cart.  And, a tough utility cart add-on.  The shelves will not hold the same weight as the floor cart, but they are much stronger than most utility style shop carts.  Here are the plans.

A working wood top for the floor cart is pretty important to me.  I like the soft top, as it does not scratch things.  Moreover, I occasionally screw blocks to it for holding things, or to keep things from sliding.  Also, we can replace a wood top like this pretty easy when needed.  A material like poplar is not too hard, but also not too soft.

While it might seem a waste to put a utility top on a super strong shop floor cart, it is the 3-in-1 that makes it valuable.  I do not need a floor cart with high capacity very often, but there is no substitute when I do.  So, it makes a great utility base that does not take extra storage space when not in use for heavy loads.  When I do need it, loosen a few bolts, and the floor cart is free.

By using leg extensions for the utility top as the catch for securing it, the utility top still functions for tools and a mini bench even when it is not on the cart.  It is just not mobile.  The utility top is then free standing.  That is a trade-off that works for me.

( See More Solutions! for the shop in other articles, too.  Some from readers, some from us.  Or, submit one of your fun Solutions! )

Will The 3-in-1 Shop Cart Work For You?

Admittedly, the 3-in-1 system for this utility and floor cart is not right for everyone.  Many people prefer separate tools for separate jobs, and that is great – especially if you have the room for it.  If I had a bigger shop with more storage space, that is probably how I would want too.

Anyway, if you need a super tough floor cart, build that part without building the shelves.  No problem, and you have it.  Or build just the shelves for a strong, mini worktop.  If all you need is a good utility cart (not much weight), these plans are a little overkill.  It is all good.

Worktop, Floor, Utility Cart

As with all our plans, we encourage customization.  Build it to meet your needs.  If these plans offer you something of value, they are here for you.  If it does not quite meet the mark for your needs, then hopefully we have stimulated some better ideas.  Perhaps you can build something awesome of your own design.

As with all things, we are here to help you succeed.  Feel free to scan below to see other articles of interest.

Good luck with all your projects!

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