Step: 1
Start by cutting each side of the Job Buddy from 3/4” plywood
Top/Bottom: (2) 42-1/2” x 12-1/2”
Front/Back: (2) 42-1/2” x 13”
Sides: (2) 11” x 13”
Step: 2
Next, take the front panel (42-1/2” x 13”) and measure out the window area. Using a ruler and straight edge, measure and mark a rectangle 2-3/4” from the top and 16-1/2” from the sides.
Step: 3
Drill two holes inside opposite sides of the rectangle you’ve just drawn. Use the holes as the starting point to cut out the opening with a jig saw.
Step: 4
Using a router, make a rabbet cut 1/4” deep and 1/2” wide around the front facing side of the opening. The metal mesh in Step 9 will inlay here for a cleaner look. Repeat steps 3-4 for the opposite side of box.
Step: 5
Select the top piece (42-1/2” x 12-1/2”) and cut out the top opening. Leave 1-1/2” of plywood around three sides and 10” at the end.
Step: 6
Assemble all pieces to make the box. Apply glue to the 13” edge of side pieces. Drill pilot holes and drive screws through front/back panels.
Step: 7
Apply glue to top and bottom of box when assembling these pieces. Any screws that you put down through the top piece of plywood will be seen, so consider using pocket screws for the top piece. The rest of the pieces can be face-screwed, because they will be covered up.
Step: 8
To trim out the sides of the box cut the following: From one 1”x4”x8’ board cut twelve separate 7-1/2” boards. From two 1”x4”x8’ boards cut four separate 42-1/2” boards. Finally, from one 1”x4”x6’ board cut four separate 14” boards.
Step: 9
Using metal shears, cut a piece of metal mesh 10-1/2” x 8-1/2”. Set the metal in the middle frame opening and secure with hot glue. Using glue and brad nails, fasten all trim to the outside of the box.
Step: 10
Cut 4 pieces of 2” angle iron 14-1/2” long. Drill pilot holes and attach each piece to the corners of the box.
Step: 11
Cut two pieces of 2” angle iron 14” long. Drill pilot holes and attach to the top sides of the box.
Step: 12
Cut two pieces of 3” iron bar 12” long. Drill pilot holes and attach to the top of box.
Step: 13
From 3/4” plywood cut a piece 32”x16” for the top lid. Attach to top of box with 30” continuous hinge.
Step: 14
Attach casters to bottom of cart.