This sheet goods / cutoff cart is designed to hold a wide variety of wood products, in both sheet and hardwood stock cutoff sizes and is intended to be built with the following mateirals.
2 @ 4' x 8' sheets of 3/4" plywood. Pick your grade. I personally would go with cabinet grade stock, I have seen these done wiht sheating... Up to you.
4 @ heavy duty casters of your choice. I am still digging for suitable casters.
Wood screws and glue.
In preparation for my own build, I have fine tuned the cutlist to match what Jerry is showing on his project page. I have also created this cutlist by taking the individual model components and laying them out so that they make a full sheet of plywood, so I know, aside from kerfs, that everything works dead on...
The cutlist was modified to show 6x6 caster blocks instead of 7x10. The 7x10 used too much material, and didn't offer any real advantages over 6x6. Another option that would require just a hair more material than 2 sheets of plywood would be to make mounting cleats from 2x4 stock across the width of the cart.
This is a shop cart, any slop induced by kerfs is expected. YOU the builder will be expected to compensate for your saws own kerf.