Plywood Storage Trolley

I needed a place to store large pieces of plywood left over from projects or awaiting a project start.   And to follow the direction I had taken with all other large objects in the shop, it must be on wheels.   I first built a wooden trolley but after a few years it sagged under the weight and I had to build a metal framed trolley.   I call it a trolley instead of a rack because it has wheels so I can move it around.

Not too long ago I bought a storage shed, with room to store full and nearly full sheets of plywood.   I decided this was the time to rebuild the trolley.   Since I didn't need full sheets of plywood in the shop, I didn't need the depressed center of the old ply trolly, although I could have built a metal frame that way.   I welded up two 'U' shaped end pieces out of 1.5" angle, the attached them with two 1.5" angle stringers.   I added a 3/4" plywood floor with casters under the corners and a 1.5" x 1.5" (ripped 2x4) frame front and back.    

A little closer look.

From the end.   You can see the 3" casters, these are non-locking.

closer look at the frame end.   I welded up a 'U' frame out of angle for each end, then welded the two 'U's to stringers to complete the frame.

Along the back.   You can see the front and back rails are bolted on with 1/4-20 carriage bolts.

In addition to ugly welds, you can see one of the 1/4-20 carriage bolts holding down the 3/4" floor.

The Old Plywood Trolley

You can see the old plywood trolley on the right against the wall.   There were two sections, the back for full 8' tall plywood sheets and the front for pieces 48" or less.   Since the ceiling in the shop is just slightly over 8', I had to make a depressed center for the tall section of plywood.   This pic was taken not long after I built the trolley, note the front rail is still vertical.

Here it is pulled away from the wall   You can see the two verticals and top cross piece that support the tall sheets and allowing them to lean back slightly.   This pic was taken several years after I put it in service, note the front rail is leaning out at a drastic angle.

This is a pic of the back end of the trolley's base, you can see the two verticals *8' long' separated by a horizontal brace (2x4), you can also see the depressed center for the bottom edge of the tall stuff.

Here is most of the trolley's base, you can see the depressed center and the front raised above the casters.

The top of the verticals separated only a 1x2, the bottom is about 3" apart, and the rear vertical is truly vertical.

A shot looking down ont the trolley's base, you can see how the front is sagging.

The front rail was held on by a 5" metal angle, not near strong enough.