Mobile Table saw cart for DWE7491RS

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).

Design features:

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. 

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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.

1. 35″ long 2x4s – 4 nos
2. 17″ long 2x4s – 8 nos
3. 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.

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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.

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 Just remember that the width of extension top should be sized to be within the width of the table saw fence rail.

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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?

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