I recently picked up an old Sears Craftsman 6 1/8" jointer at a yard sale, but the existing metal stand is really flimsy and needs replacing. The jointer is pretty heavy—I'd guess over 100 lbs—so I'm planning to build a simple rolling cart using 2x4s. My idea is to create two rectangular frames, one for the top and one for the lower shelf, connect them with legs, and add locking casters. Both shelves will have 3/4" plywood tops, and I might throw in some cross braces for extra stiffness.
I'm wondering: for a project like this, is it okay just to screw the joints through the side of one 2x4 into the end grain of another? If I use two screws per joint and reinforce it with cross-braces, will that be solid enough? Alternatively, would using pocket holes or corner braces provide better support?
2 Answers
Honestly, screwing into end grain should work fine for a shop cart like yours. I've built things with just butt joints before, and they held up pretty well! If you want some extra strength, consider using lap joints—just overlap some wood pieces for added support. It's not hard to do with a circular saw and a chisel, and it’ll give you a good tight fit. Plus, you can still use screws to hold everything together for peace of mind.
You don't need to worry too much about the screws if you're doing two per joint; it should be sturdy enough. But I’d suggest placing the legs inside the frame instead of the outside—this way, the weight is supported by the wood rather than just the screws. If you're looking for a cleaner look and strength, pocket holes are nice, but since they’ll be visible, why not just screw straight through instead? Saves you an extra step!
That sounds like a solid plan! I think lap joints and some screws are definitely the way to go for strength.