How to Build Your Own Rolling Chest

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Here's a great use for that scrap lumber sitting around your shop: Use it to build a rolling chest with a rustic feel.

By Matt Pierce

Rolling Chest Plans (PDF, 1MB, requires Adobe Reader)

what to do with. Looking for a way to put them to use, other than as kindling, I came up with this rolling chest covered with cast-off blocks. The box is built from ?-inch plywood and rides on industrial-duty casters (invisible, below?but they\'re there!) from a local hardware store. Pieces of fir, walnut, and oak are discreetly nailed to the surface to give the piece a rustic aesthetic.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/M2/rolling-chest-01-1212-smn.jpg", src: "/cm/popularmechanics/images/FB/rolling-chest-01-1212-lgn.jpg", srcwidth: 600, srcheight: 450 }, { id: "slide2", url: "how-to-build-your-own-rolling-chest-2", slidetype: "image", title: "Construct the Box", description: "You can build this relatively simple project with just a circular saw and drill driver, but it\'s even easier if you have a small table saw, a dado blade, and a pneumatic finish nailer. I also used two Kreg accessories to build the box: a circular saw guide and a pocket-screw jig.\n\n

\n\nBegin by ripping and crosscutting the sheet of plywood into the sizes shown in the downloadable plans. Label the pieces for the four sides of the box, making sure to mark which edge has the smooth factory finish; this edge forms the top perimeter of the box. Cut the four triangular blocks that will serve as the corner gussets; the wheels will be fastened to the gussets, which also help to strengthen the box. Also, bore the pocket-screw pilot holes into the panels.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/lG/rolling-chest-02-1212-smn.jpg", src: "/cm/popularmechanics/images/5k/rolling-chest-02-1212-lgn.jpg", srcwidth: 450, srcheight: 600 }, { id: "slide3", url: "how-to-build-your-own-rolling-chest-3", slidetype: "image", title: "Cut the Groove", description: "Using a router with a straight bit or a table saw with a dado blade (set the cutting depth to 3/8 inch), cut into all four panels the groove that will receive the bottom panel.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/2y/rolling-chest-03-1212-smn.jpg", src: "/cm/popularmechanics/images/0O/rolling-chest-03-1212-lgn.jpg", srcwidth: 600, srcheight: 450 }, { id: "slide4", url: "how-to-build-your-own-rolling-chest-4", slidetype: "image", title: "Assemble the Parts", description: "Assemble the parts, sliding the bottom into its groove.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/Cv/rolling-chest-04-1212-smn.jpg", src: "/cm/popularmechanics/images/ET/rolling-chest-04-1212-lgn.jpg", srcwidth: 600, srcheight: 450 }, { id: "slide5", url: "how-to-build-your-own-rolling-chest-5", slidetype: "image", title: "Complete the Assembly", description: "Complete the box assembly by driving the pocket screws into their pilot holes. Flip the box so that it\'s bottom side up, spread some carpenter\'s glue in the corners, and press the gussets into place. Let the glue cure.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/gW/rolling-chest-05-1212-smn.jpg", src: "/cm/popularmechanics/images/z5/rolling-chest-05-1212-lgn.jpg", srcwidth: 450, srcheight: 600 }, { id: "slide6", url: "how-to-build-your-own-rolling-chest-6", slidetype: "image", title: "Cladding the Box", description: "Gather your best pieces of scrap wood and arrange them on your work bench in dimensions approximating each side of the box. Use scraps that vary in color, shape, and texture?the greater the variation, the more visually striking the cladding will be. Don\'t belabor the initial arrangements; you\'re going to have to make adjustments where the parts overlap at the corners; the sides may overlap the end pieces or vice versa. \n\n

\n\nTo refine the fit of the scraps, clean them up one at a time on the miter and table saws. Starting at the top edge and working down, nail the blocks in place with a pneumatic finish nailer. Work your way around the box, attaching the pieces with an appropriate size nail. I used ?-inch and 1?-inch; choose your nail lengths carefully so that none penetrates the inside of the box. If a nail does jut through the surface of the interior, clip off the tip with diagonal pliers and tap the stub into the plywood.\n\n

\n\nAfter the box is clad, remove sharp edges and splinters with a rubber block and 120-grit sandpaper.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/ER/rolling-chest-06-1212-smn.jpg", src: "/cm/popularmechanics/images/aI/rolling-chest-06-1212-lgn.jpg", srcwidth: 600, srcheight: 450 }, { id: "slide7", url: "how-to-build-your-own-rolling-chest-7", slidetype: "image", title: "Finishing Touches", description: "Drill a hole for a caster stud through each corner gusset at the bottom of the box. Hold a Teenut on the inside of the box, then tap it down, turn the caster stud into it, and tighten, pulling the sharp end of the Teenut into the box bottom. If you use a caster that requires a wrench to sock down, be careful not to overtighten. Firm resistance indicates that the Teenut is properly seated and the caster is fully tightened.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/Q6/rolling-chest-07-1212-smn.jpg", src: "/cm/popularmechanics/images/wp/rolling-chest-07-1212-lgn.jpg", srcwidth: 600, srcheight: 450 }, { id: "slide8", url: "how-to-build-your-own-rolling-chest-8", slidetype: "image", title: "Coat the Box", description: "I completed the project with a coat of boiled linseed oil, a natural finish that works as well today as it did a century ago. Wipe on one coat, let it dry, and then apply a second coat. As the box ages, the finish will mellow to a warm amber-brown color.\n\n

\n\nRemember to treat any rag soaked with finish as a fire hazard. Hang it over a line to let it dry or soak it in a bucket of water; don\'t just throw it into the trash can, where fumes may collect and lead to spontaneous combustion.\n\n

\n\nAfter the somewhat nutty odor of the linseed oil has dissipated, take the box inside and you\'re ready to roll.", credit: "Shawn Records", sourceid: null, sourcename: "", sourceurl: null, sourcelogo: "", thumbsrc: "/cm/popularmechanics/images/DV/rolling-chest-08-1212-smn.jpg", src: "/cm/popularmechanics/images/UM/rolling-chest-08-1212-lgn.jpg", srcwidth: 600, srcheight: 450 } ] };

Like most woodworkers, I've got more scraps in my shop than I know what to do with. Looking for a way to put them to use, other than as kindling, I came up with this rolling chest covered with cast-off blocks. The box is built from ?-inch plywood and rides on industrial-duty casters (invisible, below?but they're there!) from a local hardware store. Pieces of fir, walnut, and oak are discreetly nailed to the surface to give the piece a rustic aesthetic.

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