Tool Cart (Inspired by Adam Savage): Upgraded!

A few years ago, I watched a YouTube video where Adam Savage introduced his tool cart, and I was immediately impressed by the design.

I loved the concept so much that I decided to build my own version of it. In my first design, I made improvements in two key areas where I felt Adam’s cart fell short:

First, the structure of his tool cart seemed a bit flimsy. You can see in his video that the cart wobbles when touched, likely because he used thinner plywood. I believe using thicker wood would have made it sturdier.
Second, I noticed there was a lot of wasted space in his design, as well as many others online. The gaps between the two rows of tools were essentially unused space, which could be optimized.

So, I built my own modified tool cart and addressed these issues by adding some internal storage rooms to make use of the empty spaces.

I love the tool cart. It makes all my smaller tools easily accessible and visible, so I can quickly find what I need. However, even with this design, I’ve identified a couple of shortcomings:

I designed multiple layers of internal storage compartments, but accessing them is difficult because the tools block the way.
When I was building the tool cart, I rushed through the process and ended up doing a sloppy job, resulting in poorly made holes for tool placement. Fortunately, that's an easier fix.

A well-known quote from Adam Savage's video "Drawers are where tools go to die" is often cited by those who avoid using drawers for tool storage. However, he later revised this statement, saying, "Drawers are great if each drawer is dedicated to a single purpose." Inspired by this, I upgraded my second version accordingly.

Below let me walk you through how I make the 2nd version of this tool cart.

*Note:

I didn’t include specific dimensions in this Instructable because everyone’s needs are different, and a fixed set of measurements might not work for everyone. Instead, I’m sharing the concept and design, giving you the flexibility to adjust the dimensions as needed. Let's get creative and build your own custom cart!

Supplies

Tool List

- Clamp

- Jig Saw

Material List

- Plywood

- Wood Glue

- Screws (#8 2” or 2 ½”):

- Brad nails (2”):

- Draw slides

- Shellac

- Polycrylic Water-Based Protective Finish Satin

Cut the Side Panels

Cut the lumber to the shape of the 2 sides of the panel
Use a jig saw or a router to cut out the openings for the drawers and the handle.

Cut the Lumber for the Level Dividers

Cut the lumber for the level dividers, i.e. the horizontal boards that divide layers.

We will need specifically the top and the bottom boards to assemble the frame in the next step.

Assemble the Frame

Assemble the 2 side panels, the top, and the bottom board.

Use clamps, 90-degree-angle jigs to help hold it upright (or find helpers). Use glue and a brad nailer to fix the lumber in place before using the screw to finally secure them.

Drill Tool Holes on Level Dividers

Drill holes on the level dividers. They will be the toll insert holes.

Depending on the tools, add some channels to make it easier to slide in the tools.

It is easier to do this step at this point than later in the final stage.

Make Level Divider Walls

Cut the "level divider walls", i.e. the vertical part of the internal compartments. Install the drawer slides on these boards. Doing it at this point is much easier than later.

Assemble the Main Structure

Assemble all levels, one level by another. For example, starting from the top level, assemble the divider walls and then the divider. Use glue and brad nails to fix the lumber in place before the final screwing.

At this point, the main structure of the cart is done!

Tips:

1. I used wood filler to fill the imperfections (holes) on the wood

2. Then I used screws to reinforce the structure

Assemble the Drawers

When making the drawers, test fit if they can go into the compartments smoothly before the final assembly.

Also, make sure to leave enough gap space to accommodate the thickness of the drawer slides.

Make Drawer Front Panels

The drawer front panels are of trapezoid shape and with edge rounded off. If you don't want to deal with this more challenging shape, simply cut out rectangular shapes.

Attach the front panels to the drawers. Also, attach the drawer handles. For my case, I designed a special handle using the dowels I made previously in this Instructables.

At this point, all of the main components of the cart are done!

You can make the cart look more professional by sanding and painting it.