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Check existing supplies first. Quantities are planning allowances; take hardware templates and actual measurements.
| Qty | Item | Notes |
|---|---|---|
| 1 full sheet + 1 project panel | 3/4 in cabinet-grade, sanded plywood | One usable 48 × 96 in sheet plus one true 24 × 48 in panel. Inspect flatness, veneer and usable dimensions. If cleanup leaves less than 24 in, buy larger stock; two full sheets are the fallback. |
| 5 boards; optional 6th | 2×4 × 8 ft, dry straight softwood | Frame and eight caster blocks; actual 1½ × 3½ in. Extra board covers defects and practice. |
| 1 board | 2×6 × 8 ft, dry straight softwood | Four bracket-backer blanks, initially 12 in long. Final length and holes follow the selected bracket. |
| 2 boards | 1×2 × 8 ft, straight stock | Rear-panel cleats and two nonstructural dowel-practice joints; use leftovers first. |
| 4 | 4 in dual-locking swivel casters | Both wheel and swivel must lock. Confirm plate/hole pattern fits reinforced pads, brakes stay reachable, and hardware clears full swivel. See capacity note below. |
| 4 brackets / 2 pairs | Positive-locking folding worktop brackets | Select a manufacturer-approved 24 in projection, compatible 24 in panel width and wooden backing installation. Obtain hole template and fastener instructions before final backer cuts. Pair rating is not a cart rating. |
| 100-count box | 2½ in coarse-thread Kreg pocket screws | For actual 1½ in 2×4 stock and a compatible standard Kreg jig. Do not substitute drywall screws. |
| About 50 | 1¼ in wood screws | Plywood-to-frame and cleats where actual thickness permits; predrill. Do not use these as generic caster/bracket fasteners. |
Store notes / prices: __________________________________________________________
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| Qty | Item | Notes |
|---|---|---|
| About 24 | Rated structural wood screws for pads | Select length after stack-up for at least the manufacturer’s required embedment into rail side grain. Nominal 3½ in may suit a 2¼ in pad; verify against the actual framing and avoid pocket screws. |
| 16 sets, if four holes per plate | Caster through-bolts, washers and locknuts | Diameter follows plate; length = pad + plate + washers + nut with full thread engagement. Buy after template check. Recess only as needed for a flat pad bearing surface; never cut into rails. |
| 8 sets, planning allowance | Backer-to-leg through-bolts, washers and locknuts | Two vertically spaced per backer; nominal 1/4 in is a starting allowance, subject to hardware requirements. Length suits two 1½ in layers plus washers/nut. Keep safe edge distances and clear of bracket screws. |
| 4 sets | Saw bolts, flat washers and locknuts | One compatible factory hole per foot. Diameter and length from actual saw/deck stack; washer bears flat without loading a curved casting. No drilling or enlarging the saw casting. |
| Per hardware template | Bracket fasteners and wing fixings | Approved fasteners into solid backers; wing screws must not pierce the top. If the specified fixing cannot work in 3/4 in ply, add approved backing and remeasure wing geometry. |
| Small bottle + 8 dowels | Interior wood glue; 1/4 in fluted dowels | Four dowels for two practice joints, four spare. Match the doweling jig. Glue is not a substitute for the structural fasteners. |
| 2 lengths / optional kit | Left- and right-reading adhesive tapes; T-track and compatible flip stop | One tape per wing, long enough to display its real distance from blade. Allow two 24 in track sections or cut a longer length. Confirm track, stop reach and fence stock thickness together. |
| About 8 sets | Removable fence screws/bolts, washers and knobs | Size to chosen fence mounting tabs and wing thickness; allow clearance underneath when folded. |
Bring back before final cutting: caster dimensions, bracket template and fastener instructions.
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| Qty | Item | Notes |
|---|---|---|
| 1 quart each, verify coverage | Compatible conditioner and Provincial interior semi-transparent stain | Choose a stain/conditioner system for the plywood face species and softwood. Provincial is a color, not a chemistry specification. |
| About 3 quarts, check label | Water-based polyurethane, satin suggested | Three coats on all exposed wood; optional fourth on work surfaces. Rough allowance 70–85 sq ft per coat; divide total coat area by label coverage and allow waste. |
| Assorted | 120/150/180/220-grit abrasives; finish applicators | Follow finish label for final prep and between-coat grit. Include dust removal supplies and safe finish-waste storage. |
| Check existing tools | Square, tape, straightedge, clamps, drill, bits, jigs | Also countersink, depth stops, driver, wrench/socket set, sheet-cutting guide and stable supports, PPE and dust extraction. |
Capacity selection screen: estimated total loaded cart weight ÷ 3, then choose comfortably higher-rated individual casters within maker conditions. This does not establish a cart load rating. Support long/heavy boards independently.