The following plans are for building a simple air compressor cart with a sacrificial hardboard top. It is specifically designed to fit a 16″ diameter pancake air compressor such as a DeWalt. Note a Craftsman or Bostitch will fit, but since they are 16.5″ in diameter, you may have to lean them in a bit in order to get them in. I did get my Bostitch to fit without much trouble.

If you’re a woodworking enthusiast or a DIY aficionado, you’ve likely experienced the frustration of wrestling with cumbersome air compressors and tangled hoses cluttering your workspace. Enter the air compressor cart—a simple yet game-changing solution that streamlines your workflow and enhances your overall efficiency. In this post, we’ll guide you through the process of building your own air compressor cart, providing detailed instructions that even beginners can follow. Not only will this project free up valuable floor space in your workshop, but it will also make moving your air compressor around a breeze, allowing you to focus more on your craft and less on your setup.

Building an air compressor cart is more than just a practical upgrade; it’s a smart investment in your woodworking experience. One of the key benefits is mobility—an air compressor cart allows you to easily maneuver your compressor around the workshop or job site, ensuring that compressed air is always within reach wherever you need it. Additionally, organizing your compressor, hoses, and accessories on a dedicated cart keeps your workspace tidy and reduces the risk of tripping over loose hoses or damaging equipment. With improved accessibility and organization, you’ll find that your projects run smoother, your productivity increases, and your workshop becomes a more enjoyable and efficient environment to work in.

Materials Needed

• 1 – 2′ x 4′ sheet of 1/2″ plywood (or 3/4″ if you prefer)
• 1 – 2 x 4′ sheet of 1/4″ plywood
• 1 – 4′ x 4′ sheet of pegboard
• 1 – 2′ x 2′ sheet of hardboard
• 1 – 1 x 3 @ 8′
• 1 – 2 x 2 @ 6′
• 1 – 1 x 6 @ 6′
• 2 – 1/2 x 1″ @ 4′
• 4 – casters
• 1 1/4″ pocket hole screws
• wood screws
• wood glue
• Drain hose extension (highly recommended)

Tools Needed

• Table saw
• Router with straight bit (or you can use your table saw)
• Drill / driver combo with countersink bit
• Trim nailer
• Pocket hole jig

Step1: Build the air compressor cart frame

Begin making your air compressor cart by cutting and assembling the frame using wood glue and pocket hole screws. The frame is going to consist of the following components:

• 2 front uprights: 1 1/4″ x 1 1/2″ x 30″. These are cut and milled down from the 2×2. Note the 1/2″ dado needs to be cut on the 1 1/4″ side. The dado should be 1/4″ wide to accept the pegboard, and set back 3/4″ from one edge.
• 2 back uprights: 4 3/4″ x 3/4″ x 30″. These are cut from the 1×6, and have a 1/4″ x 1/4″ dado set 1/2″ from one end.
• 4 side rails: 2″ x 3/4″ x 14 1/4″. These are cut from the 1×3. You can opt to leave them at 2 1/2″ wide, or mill them down. These should also have 2 pocket holes drilled on each end.
• 1 front bottom rail: 2″ x 3/4″ x 16″. This is also cut from the 1×3, and again, you can opt to mill down to 2″ or leave at 2 1/2″. Drill two pocket holes on each of this piece as well.

Once all of the pieces are cut, use wood glue and pocket hole screws to assemble the pieces as in the diagrams below. Note that for the front uprights the dado should be aligned inwards to face the back uprights with the 3/4″ shoulder on the outside. For the back uprights, the dados should face each other (inwards) and be aligned towards the middle of the frame.

Step 2: Attach the cart bottom and the panels

Once you have the frame assembled on your DIY air compressor cart, use wood glue and the nail gun to attach a 18 1/2″ x 20 1/2″ sheet of 1/2″ plywood as the cart bottom.

The 1/4″ plywood back wall should just slide into the dados in the back uprights. The pegboard panels should slide into the single dado of the front uprights, and then get stapled into the 1/2″ shoulder remaining on the back uprights.

Step 3: Build and add the top with hangers

The next step is adding the top of the cart. The main piece is again 18 1/2″ x 20 1/2″, but before we attach it we’re going to build the hangers. The hangers can be made from either 1/2″ plywood or 3/4″ plywood. The key factors are leaving a 3 to 3 1/2″ gap in between the vertical boards to leave room for the nail gun heads, and at most a 2″ gap between the horizontal boards. I’ve drawn the design using 1/2″ vertical boards as it exactly lays out to 3 1/2″ between them when creating four hanging slots.

Use wood glue and wood screws to attach all of the pieces. Then you should be able to drop the top into place and attach using wood glue and the nail gun.

Step 4: Add top trim, hardboard, and caster

Now that the top of the air compressor cart is attached, we’re going to add four pieces of 1″ x 1/2″ trim. You’ll want to leave the trim sit 1/8″ higher than the plywood top to leave a lip to hold the sacrificial hardboard that will both hide the screws and also allow for easy replacement if it gets cut, wet, glue residue, etc…

Use wood glue and the nail gun to attach the trim, but just set the hardboard in place. The fit should be snug so that it doesn’t move. The last step of assembly is to predrill and screw in your casters. I prefer locking casters, though admittedly I rarely ever actually use the locking function. Of course, you may want to add some shelves or hooks to organize your accessories as you see fit. We didn’t define how those shelves should be laid out, as everyone has different needs.

One more thing I’d highly recommend is to drill a 1″ hole in front of the plywood back wall to allow for a drain hose extension to be fed out. Having take the compressor out every time you want to drain it almost defeats the purpose of having your compressor on a cart. If you add an extension you can drain the compressor by simply toggling the lever on the end of the sticking out by the back of your cart.

At this point, all of the assembly is complete on the DIY air compressor cart. I like to add a few coats of boiled linseed oil to the sacrificial hardboard top to make it more durable and easier to clean. I also recommend adding a few coats of finish to the rest of the wood. A good coverage of polycrylic or polyurethane will help seal the wood and extend the life of the air compressor cart.

I hope you enjoy these plans and find them useful. Please check out our other jig and workshop plans. If you have any questions, leave us a comment below. And don’t forget to submit your build if you use these or any of our plans to build something of your own.

* This post may have affiliate links, which means I may receive commissions if you choose to purchase through links I provide (at no extra cost to you). As an Amazon Associate I earn from qualifying purchases. Thank you for supporting the work I put into this site.