I am slowly adding tools to my workshop and this table saw is one of them. Soon after building few projects, I realized that I need to build a mobile cart for it. The saw does come with a rolling stand but in order to move the saw, you have to fold the legs and it was little hard to do it by myself. So, I decided to build this mobile table saw cart for my Dewalt DWE7491RS. This is one of the first shop furniture that I am building to enable a smooth workflow and make it easily movable when needed.
Like a lot of DIYer, part of my garage is my workshop. So, while I am not working, all the tools and workbench needs to be tucked away closer to the wall to clear-up space. So, considering that in mind and the fact that we move a lot, I am building this cart and a few more shop furniture(in future).
This table saw cart has a folding extension table, storage underneath, heavy duty castors for mobility and the brakes keep the cart perfectly stable while using the saw. I did not design an outfeed table for this cart, as I am planning to use workbench as my outfeed table to save space.
- 2x4s – 8ft length – 4 nos
- 3/4″ thk plywood – 4×4 sheet
- 1/4″ thk ply or MDF
- Heavy duty Castor wheels with brake
- Foldable bracket
- 2-1/2″ pocket screws
- 3″ wood screws
- 2″ wood screws
- Miter saw
- Table saw
- Power drill
- Pocket hole jig
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Measurement: This table is designed for the model DWE7491RS. Size: 35″L x 24″ B x 32.5″H. You can easily modify the dimensions to suit your saw size. The design requires 2x4s to build the frame. So, remember to consider the actual size of the 2×4 lumber, which is 1-1/2″ x3-1/2″.
Step- 1 – Cuts for understructure
The understructure frame is made with 2x4s. Follow the below list and cut all the 2x4s.
- 35″ long 2x4s – 4 nos
- 17″ long 2x4s – 8 nos
- 11″ long 2x4s – 5 nos
Step – 2 – Assemble
To assemble the structure, I used pocket holes. Drill pocket holes on all the 11 inch and 17 inch pieces. Then, using 2-1/2″ pocket screws assemble the frame in following order.
Step – 3 – Add castors
Place the understructure frame upside down and add 3/4″ thick plywood pieces on four corners before installing heavy duty castors.
Step – 4 – Paint
You can skip this step if you prefer to leave the cart in natural color. I wanted to paint mine. So, primed the surface and painted two coats.
Step – 5 – Install Top, bottom & sides
Cut and install 3/4″ thick Plywood – 36″x24″ (1no) for Top & 21-3/4″ x 11″ (2nos) for sides. For rear fascia and bottom, I used 1/4″ plywood/Mdf. To get perfect fitting, I suggest that you take exact measurements of the built understructure frame and cut the above mentioned side, rear and bottom plywood pieces.
Note: The side and bottom panels are sized 1/2″ less in the front, as I have plans to add a drawer in the future.
Step – 6 – Install Folding Extension top
To build the frame for the folding bracket, need to cut 12-1/4″ long 2x4s – 3nos & 16-1/2″ long 2×2 – 2nos. Install them as shown in below image.
Then install the folding bracket & 3/4″ thick plywood for top. The 5″x 21-1/2″ plywood is the fixed top and 16-1/2″x 21-1/2″ plywood is the folding top.
Just remember that the width of extension top should be sized to be within the width of the table saw fence rail.
Step – 7 – Smooth the edges (optional)
Use round bit and route the edges of the 3/4 inch plywood top to avoid sharp edges.
Step – 8 – Sand and seal
Finally, sand the whole cart and seal with clear polyacrylic sealer or paint in any color you like!
Securing the table saw? I was initially planning to secure the table saw in location by fixing 2x2s around it. But the table saw’s own weight seems to be keeping it in place & it is completely stable. May be I will add some anchors later. But, as of now, it just sits without any anchor and I have not had any issues using it.
This table saw cart has a huge open shelf storage underneath. It can hold the jigs for table saw and may be in future I might add a drawer there.
Mobile Table saw cart for DWE7491RS has turned out to be a good addition to my workshop. I can move it so easily wherever I want and it perfectly stable when the brakes are ON.
Hope this tutorial is useful for you to build your own. Happy making!.
Are you interested in building a lap desk?
Or a customizable shelf?
April 23, 2022 @ 7:59 PM
I purchased your plans for the table saw cart. I noticed you had fastened a piece of wood on the bottom shelf in the rear of the cart. Would you provide me with the measurements and the reason you secured that piece of wood. Thank you.
May 2, 2022 @ 4:12 PM
Hello Roy, I guess you are talking about the four plywood pieces I attached on the rear of the frame. That wood piece is only to anchor the castors properly to the frame. You can cut the wood piece to be at least 3 inches bigger on all sides than the castor plate.
July 27, 2022 @ 10:05 PM
Great design. I built it with some modifications and it came out great. I did come across an issue (which I am wondering how you didn’t run into the same problem) that with this design it is impossible to release the riving knife using the left side release lever without needing to pull out the tablesaw from the cart since the lever is blocked by the frame for the folding bracket AND the bottom of the 3/4″ plywood mounted to the frame. To resolve this, I lowered the 2×2 on the frame by several inches AND used a router to remove about 1/4″ from the bottom of the plywood to make room for the path of the riving knife release lever. Hope this was clear…
I also strongly recommend adding a router table extension to the other side of the table which maximizes space! I found a great video online which I followed.
Thanks for the post.
August 3, 2022 @ 9:54 AM
Good point Ilan. I did not have the need to remove my riving knife so far. I prefer keeping them attached for safety reasons. Except when I need to use dado blade. Which is rare for me. Thanks for suggesting a work around to access the release lever. It will be helpful for my viewers. Thanks!
August 24, 2022 @ 4:46 PM
Can you share the Router table video you used? Please
July 30, 2022 @ 3:00 PM
Thanks so much for sharing. I finished mine today and I think it’s going to make using my table saw a lot easier.
August 3, 2022 @ 9:44 AM
I am glad to hear Mike!!
January 15, 2023 @ 11:52 PM
Thank you for sharing your design and instructional video. I just finished my build today and love it. Much appreciation to you.