I acquired a bunch of tools this year and quickly had nowhere to put them all. I saw a plan from FixThisBuildThat for a single flip-cart that holds two tools, one on the top and one on the bottom.
I don’t have a ton of shop space, and I wanted a big assembly table that could double as an outfeed table for my table saw. So I came up with the brilliant idea of doing a double flip-cart, where each section houses only 1 tool so that I could utilize the opposite side as a large workspace!
I used Brad’s plans for the most part. Here is where I deviated. I wanted a deeper table so that I could have a 36” workspace. I also increased the width of the planer-side for my DW735 and decreased the width for my RIDGID Sander. I increased my wheel size from 3” castors to 4” castors so that the edge of the top would be level with the top of my table saw. My locking mechanism needed to change as well because Brad’s cool locking knob wouldn’t work in my center section as it would interfere with the second flip-top. So I used a quick latch receiver hitch pin, which worked really well! Here is my rough drawing, material, cut and cost list.
I needed to move my hole for the tube up so that the top of the flip-top would be level with the sides. This will be dependent on your tube’s external diameter. Mine tube was 1 1/16”…I had a 1 3/16” Forstner bit so drilled my 3 holes, one at a time, trying to check and double check that the holes stack perfectly on top of one another. Find the radius of your tube (diameter divided by 2) and add to your 3/4” top to find the center point of your drilling location from the top.
For each flip-top section, I ripped 2×2’s into 1 1/16” pieces to match my tube’s external diameter. I used these pieces as the internal bracing.
After I had the center tube supports, I put the actual tool where I wanted it and marked the location for the bolts. I made a mistake at this step and centered the tool. Instead, make sure all your parts fit within the plywood rectangle. My handle on my planer is just over the edge, so I need to remove it prior to flipping 🤦🏻♀️. But you can avoid this by not making such an idiot mistake!!
After you mark your 4 bolt locations, I took the smallest drill bit I had and made a hole. Now I know the exact location of where to put the internal bracing, making sure to keep those areas clear of screws as well. I glued and screwed each piece of bracing.
I screwed the top piece of plywood on, making sure to avoid the screws from the internal bracing. I used a 7/8” Forstner bit on the side of where the bolt head will go (using the original tiny hole I drilled earlier for location) to recess the head. I also found some 7/8” plastic caps that will plug this hole. After recessing is done, I drilled a 5/16” hole through to the other side, making sure to keep the drill as straight as possible.
Then came the fun part…threading the pipe through the 3-upright panels and the two flip-tops!! I ended up turning the base (constructed exactly as Brad did it in his plans) on its side, sliding the flip-top sections in-between the uprights, lining up the holes with a flashlight and rubber mallet, and threading the pipe! I screwed on some 3/4” galvanized caps to prevent the pipe from falling out.
At this point, I marked the holes for the locking pins, drilled holes and inserted the pins. Now I could easily bolt the tools to the flip-tops!!
I’m in the process of finishing up the drawers, but will spare you the details as Brad’s drawers are much nicer than mine! The only noteworthy aspect of my drawers is that since I made a much deeper cart, I decided on two drawers per section, so 4 drawers total!
I hope this helps someone on their own shop-organization journey!!