Tuesday, November 15, 2011

We're on a Roll: Factory Cart Completion!

Way back in August, I wrote this post about potential projects using plans by Ana White.  One of the projects I mentioned was a factory cart.  We completed our own factory cart recently using Ana's plan as a starting point.  We ended up tweaking our table to look more like the table in this image:

(Ana's plans create a shorter table with no overhang on the table's top.  We made our table taller by using 1 x 10's for the sides instead of 1 x 6's, and we added an extra board across the top to allow for some overhang.  Our top boards were also slightly longer than Ana's plan called for to allow overhang on the entire table.)

We used:
2 - 1 x 2 Boards 8' long
4 - 1 x 6 Boards 8' long
2 - 1 x 10 Boards 8' long

Here was our cut list at Home Depot:
4 - 1 x 2 @ 46"
2 - 1 x 6 @ 23.5"
9 - 1 x 6 @ 26.5"
2 - 1 x 10 @ 47.5"
2 - 1 x 10 @ 23.5"

Here are a couple progress shots:

We sanded and distressed the wood after it was put together.  We used bags of screws, nails, hammers and paint lid openers to give it some character.  As for the stain, I wanted it to look old and weathered, so I used a combination of Minwax's Ebony and Special Walnut.  The Ebony was very dark, so I applied a small amount of it after wetting down the boards, and then I quickly wiped it off.  The result was a grey stain, which I went back over with Special Walnut.  I finished it off with a couple coats of Minwax Polyacrylic in Satin.  

We bought the casters at Northern Tool and Equipment:

They were expensive at $13.99 per 6 inch fixed caster.  It was the best price I could find online or elsewhere, especially considering I didn't have to pay any shipping.  We debated between using a 5 inch vs. 6 inch caster, but in the end I much preferred the way the 6 inch caster looked.  Originally, we had planned to purchase swivel casters to make the table easier to move, but they were $17.99 per caster, and when we thought about it, we figured we would probably be stubbing our toes on the casters when they weren't aligned with the table if we went the swivel route.  We ended up spraying our casters with oil rubbed bronze spray paint only around the wheels (I may end up spraying the entire caster, but I wanted to try the two colored look for now.).  I think they turned out fantastic!  The casters really make the factory cart.  

Here is how the factory cart looks as our new coffee table:

Initial Carving:)!

It's in our great room now, but it may move to the basement or the sun porch at times, as well!  The big, flat surface has been great for crayon time, board game time and project time.  It is the perfect height for our couch, and the kids love to push it around (in only two directions thanks to the fixed casters).  And it was substantially cheaper than purchasing a vintage version or a Restoration Hardware cart.

Project Cost
Wood: $40
Stain: $10
Casters: $56

Total: $106

Has anyone tackled one of Ana's plans before?  

Linking up to Finding Fabulous.
Linking up to Miss Mustard Seed.
Linking up to Thrifty Decor Chick.
Linking up to Passionately Perfect.


  1. You are having the most fun of any mom that I know who gave up her career to stay at home with the kids!

  2. fabulous! thanks for the details...especially about the casters! always looking for good sources!

  3. This is so wonderful. I love the ORB-sprayed wheels. I'm inspired!

  4. Your cart looks amazing! I saw a vintage cart at High Point furniture market and have wanted one for my home ever since. I wonder if my husband and I could pull this off.

  5. This is just awesome!! I LOVE those wheels too, and I haven't come across your source when I have done some internet searches for big casters. Great job!

    PS I host a linky party every Friday-Sunday, I would love if you stopped by to link up. Thanks!

  6. Wow, what a great table! I especially like your initial carvings, what a great bit of character. I also love the graphic rug...could you share a source for that?

  7. Thanks for all the positive feedback everyone! This really was a fun, easy project...anyone could do it!!

    Jennifer-The rug was from Home Goods in May 2010. At the time they had it in a few different colors. I haven't seen any there lately, but you never know what might turn up at that store:)!

  8. Wow! I just left you, returned to Thrifty Decor Chick, spotted your project and bam, I'm back! Love the project. Amazing. I'm a follower now ...

  9. I love the cart!! What an awesome job...and the carving are so cute!! I'm your newest fan!!!

  10. Thanks Sherika! I just linked a couple of my projects to your blog! Have a great weekend.

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