In preparation for building the rack, I trimmed the rounded edges from all fourteen 2x4s (plus one extra one in case I needed it), resulting in 3 1/4” x  1 1/2" stock. This trimming was wholly unnecessary, but I find round-shouldered boards aesthetically displeasing. (I did trim away some dinged and dented material, though.)  I didn’t run the trimmed boards through the planer to square them up.

Then I marked the locations of all the parts on all the boards and made as many 90-degree crosscuts as possible, mainly to reduce the boards to manageable lengths. I deferred the 5-degree cuts until later, so I could do them all at the same time.

Prior to construction, I bought six heavy-duty fixed casters. Grizzly had them on clearance for $7.84 each, which is a great price. They have 4” diameter, 2” wide wheels and 1/4" thick steel mounting plates and arms. These things are beasts. I didn’t weigh them, but they’re in  4-5 lb. range.

The base consists of an outer frame of 2x4s with three beams/joists connecting the short ends, and blocking connecting the joists. I had to add filler strips to the sides to accommodate the width of the casters’ mounting plates.

With the blade raised to its maximum height, I could almost cut the bevels on the joist ends.

I recently bought a Taylor Tools drill-press-based sharpening kit, and, for the first time ever, I have sharp chisels, so I used one to remove the material the saw left behind. I know it’s only soft pine or fir, but that was satisfying.

To finish the base, I added the blocking between the joists.

I debated adding the casters at this time versus waiting until later. (It’d be easier to install them now, but then I’d have to resist the temptation to ride it like a skateboard, and I’d also have to do something to keep the base from rolling as I added the rest of the frame.) I ended up installing them later, but this is a natural place to describe them. I positioned them about 1/8” from the outside edges. (There was some variance in the edge-to-outer-joist measurements, so I thought this approach was the best way to keep all the casters parallel.) I used 1 1/4" long, 1/4” lag screws with washers to attach them.