Step 1. Mark All Lumber (Cuts + Placement)
Mark all boards for both cuts and placement before cutting anything. Vertical Supports (36" boards): Mark rung placement at 15" and 32 1/2" — these marks indicate the bottom of each rung. IMPORTANT: Place an "X" on all waste sections before cutting. See project PDF for more details.
Step 2. Cut All Structural Pieces
Use miter saw to cut all structural pieces. Cut (8) vertical supports @ 36". Cut (4) horizontal supports @ 68 1/4". Cut (6) pieces @ 29" (for rails — these will be ripped in Step 3).
Step 3. Rip Tote Rails (Rungs)
Use a circular saw (or table saw) to cut the 29" pieces lengthwise. Place scrap wood underneath for support. Use clamps to secure lumber before cutting. Account for blade kerf when measuring. You should now have (12) tote rails total (~1 3/4" thick after ripping).
Step 4. Build Ladders (Install Rungs)
Lay vertical supports flat on a table. Install rungs at 15" and 32 1/2" (bottom of rung aligns with marks). Ends of rungs must be flush with the outer edge of vertical supports. Create (2) outer ladders → rungs on ONE side only. Create (2) inner ladders → rungs on BOTH sides. Clamp each rung in place before fastening. Pre-drill with 1/8" drill bit, then secure with 2 1/2" screws.
Step 5. Position Ladders
Lay all four ladders on their sides on the floor. Arrange in order: two outer ladders on the outside, two inner ladders in the middle. Ensure rungs are facing the correct direction before attaching base supports.
Step 6. Attach Base (Both Supports)
Place horizontal supports on the floor. Clamp ladders in this order: two outer ladders first, then two inner ladders. Pre-drill and screw into place. Repeat for both horizontal supports on that same side. This completes the bottom structure.
Step 7. Install Casters
Attach 4 caster wheels total. Apply wood glue to the back of each caster plate before installing. 2 locking wheels → install on the base support touching the floor (front). 2 regular wheels → install on the raised base support (back). Locking wheels should always be on the front for easy access.
Step 8. Add Back Bracing (Lower)
Use scrap 2x4 pieces (~20" long). Cut 45° angles on both ends of each brace. Install at the back of the unit for stability.
Step 9. Flip Unit + Install Top Supports + Upper Bracing
Flip the unit upright onto its wheels. Check level and test movement. Clamp and attach the remaining two 68 1/4" horizontal supports. Pre-drill and screw into place. Add upper back bracing using angled scrap pieces (same 45° method as Step 8).
Step 10. Final Ceck + Test
Check all screws and connections for tightness. Slide bins (HDX 27-gallon totes) into place. Test rolling and locking wheels. Confirm unit is stable and level before use.
Safety Notes
Wear safety glasses and hearing protection at all times. Use clamps when cutting and assembling. Pre-drill all screw holes to prevent splitting. Keep hands clear when ripping lumber on the saw. Ensure unit is level before loading bins. This build reflects a real-world tested method with precise measurements and proper sequencing, ensuring consistent results and long-term durability.
Difficulty Level - Intermediate
Garage Storage Rack
This mobile storage rack is designed to hold six HDX 27-gallon totes using a ladder-style support system. The unit is compact, durable, and built for garage use, with caster wheels for mobility and back bracing for stability. Created by @TheContract_Her.
