*NEW for 2023* Custom 80/20 T-Slot Aluminum DIT cart

I finally built a new, custom DIT cart, my first new build in nearly 9 years. I haven’t had the time to learn 3D modeling, so I drew this all up on grid paper and notebooks, and built it in my garage.
It’s close to a Junior-cart sized. The targeted footprint is 40x24 inches. I prefer smaller, narrower, lower carts for a reduced footprint, mass, and better maneuverability, especially on location, and also if I need to operate it inside van, or hump it up a flight of stairs. Shorter height is also necessary because of my van’s 52-inch height at rear doors.
The casters are inset by 3/4-inch from the corners to allow for easier replacement, and I use tool box drawer liner non-slip rubber throughout the cart’s flat surfaces. There are additional 1-inch profile rails stiffening the lower deck and providing mounting points for the 4U rack drawer between the casters. I could have gone with 8-inch casters but this would have left me with too little ground clearance for a 4U drawer.
I designed the lower-deck-to-work-surface height to eventually accommodate up to an 8U rack of at least 20-inch depth, for a planned future upgrade to a Mac Studio and DC power bank.
Improved on-cart storage was a priority with this build. My previous cart was littered with small plastic drawers, too many small storage bins, a padded AKS bag hanging off one side, and an open tool-tote. It was too chaotic and dispersed. I chose lightweight Aluminum Rack drawers from Penn-Elcom, and mounted them directly to the backside of the T-slots of the cart frame to recess them slightly from the front.
To the left of the upper rack drawer is a custom pull-out tray, placed about 30-inches from the floor. It slides on lockable linear bearings to extend over my lap to operate my Keyboard, Trackball, Stream Deck, and color panel.
The Cart frame is designed with the horizontal decks suspended between vertical ‘leg’ components front and rear. I used 1x2 inch rear vertical legs to allow for vertical adjustment of the monitor mount assembly and eventually, a cart-mounted blackout solution that would also bolt to and slide upon the outer slots of the rear vertical cart legs. Depending on the details of the framing joints, I use a variety of flat corner brackets, gusseted corner brackets, and plate fasteners on the cart, and try to plug any open profile ends with plastic covers. I like orange, so when I saw they had dust covers in that color, I used it in lots of locations to reduce dust and grime build up, as these t-slot profiles collect grime so easily, especially with all the atmospheric crap they pump into the air for everything now. A week on a stage and the slots and notches will fill with an alarming amount of crud. I also have a few rubber bumpers on all sides of the cart for added protection against truck walls and stake bed rails.
I have the option to mount an additional 2 monitors with a frame extension, and I utilize HP quick-release VESA dovetail mounts on all my larger video monitors.
I use small quick-release dovetail mounts and friction arms on the top deck to mount my computer GUI monitor, a 7Q, and an iPad to use as a secondary display. While a bit large, I’m currently using a Huion 16-inch pen-tablet monitor, because I like the QHD resolution and the option to use a pen, as I’ve also used Scratch a lot in the past and fine it convenient at times. I can swing this out to the side and tilt it down to keep the screen close to me yet not obstruct the view of the 7Q or the iPad. It’s pretty lightweight and can be held by a friction arm and an aluminum tablet clamp mount. For transport or wrap, I will fold them screens face-down on the top deck.
The Top Deck itself, I designed to keep fairly open when not moving. I have a 4-plug AC power strip mounted to the back rail for upper-deck power, and keep my iris controller battery charger up here. The rest of the space is for iris controllers, and to allow the DP as much space as possible. And the rug really ties the cart together, does it not?
The only thing I really don’t like about this new cart so far, is that it’s sitting here in my garage instead of working on set. I know there’s a huge drop in production volume currently, but it would be a lot more mutually beneficial to rent it out with yours truly operating it for a nice 6-8 month gig.
Email me [e-mail].
McMaster-Carr
www.mcmaster.com
Penn-Elcom R2295 Aluminum Rack Drawers
www.penn-elcom.com/default.as...
Ergotron LX HD monitor mounts
www.ergotron.com/en-us/produc...
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© Henry Keate t/a TheRelaxedMovement. All Rights Reserved

[@KevinStahl-qj5yc]

Should provide a hook for the DP's backpack... they love that.. Also, a DIT I just worked with had a 2RU shelf that was designated for the DP to put all his little bits in for the production.

[@jaescala]

Thanks for the in depth information. Great stuff! I agree, the rug really ties the cart together!

[@jgooch99]

This is nice. Thanks for sharing.

[@angelcastro_WRR]

Thank you for sharing

[@joshpark868]

Hope you're back to work by now! I'm a DP and have been carrying my Inovativ cart in my van, but I've been wanting to build out a cart using 8020 extrusions. Can you share a reason why you decided to build it this way instead of going with Voyagers which seem to be more popular among the DIT's? It's obviously more fashionable and better IMO.

[@AndersBakfeldt]

looks cool, hope things pick up ..

[@utooboobnoob]

Great cart! I can’t believe you haven’t gotten more likes or comments. Do you mind sharing the cost?

[@chrisratledge]

All told, the materials and components, including the 2 Ergotron monitor mounts and rack drawers (not cheap), the total was about $2800 USD (after tax). Obviously this doesn't include tools, and I had some brackets and hardware on hand, but likely still under $3k to build.
So not 'cheap', but vs. $4200 (pre-tax) for an Inovativ Echo 36, isn't insignificant. They're not a 1:1 comparison other than relative footprint, size. Mine isn't designed to collapse smaller for transport, it stays more or less built. However it is completely customized to my needs, and can be modified as needed.

[@jimniazi5176]

Nice breakdown. Could you please share a link of the ramp you have to load your cart in and out of your van?

[@brianvio7197]

Do you recommend the caster wheels you are using? They look like the ones from CasterHQ if I'm not mistaken. Looking to get some larger wheels for my cart build as well.