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https://www.ana-white.com/woodworking-projects/free-diy-tote-storage-rack-configurator-and-plans-ana-white

Tote Storage Rack – Cut List (est)

LEGS: 12 @ 60.5"
RAILS (top/bottom, front/back): 4 @ 97.75"
RUNNERS: 50 @ 24"
SPACER BLOCKS: 2 @ 8.5"

ESTIMATED LINEAR FEET
Legs: 60.5 ft
Rails: 32.6 ft
Runners: 100.0 ft
Spacers: 1.4 ft
Total: 194.5 ft

OTHER ESTIMATES
Distance between legs (clear opening): 17.75"
Totes to purchase: 25
Screws (estimate): 216

To figure out exactly how many 2x4s you need, we have to factor in standard lumber lengths and a woodworking reality called saw kerf (the ~1/8" of wood the saw blade turns into sawdust with every cut).

Here is the most critical detail from your list: Your rails are 97.75" long. Standard 8-foot 2x4s are only 96" long. Therefore, you cannot build this project using only 8-foot boards; you must buy at least a few 10-foot (120") boards.

Here are the two best ways to buy your lumber, optimized to minimize waste.

Option 1: Buy only 10-Foot Boards (Most Efficient)

Total Needed: 23 Boards (10-foot / 120")

Buying all 10-foot boards is actually the most efficient use of linear footage for this specific cut list. Here is exactly how you will cut them:

• 4 Boards (The Rails): Cut one 97.75" Rail from each board. (Leaves about 22" of scrap per board).

• 12 Boards (The Legs + Runners): Cut one 60.5" Leg AND two 24" Runners from each board. (This perfectly utilizes 108.5" of the board, leaving ~11" of scrap).

• 7 Boards (The Remaining Runners): You need 26 more Runners. You can comfortably get four 24" Runners out of a 10-foot board (factoring in the saw kerf). $26 \div 4 = 6.5$, so you need 7 boards to finish the runners.

• The Spacers: Cut your two 8.5" spacer blocks from the scrap leftover from the rail or leg boards.

Option 2: The Mixed Strategy

Total Needed: 4 Boards (10-foot) + 25 Boards (8-foot)

If 8-foot boards are significantly cheaper or easier to transport, you can buy a mix.

• 4 Boards (10-foot / 120"): Use these exclusively for your four 97.75" Rails.

• 12 Boards (8-foot / 96"): Cut one 60.5" Leg AND one 24" Runner from each board.

• 13 Boards (8-foot / 96"): Use these for your remaining 38 Runners.

  • Important Woodworking Rule: Because of the 1/8" saw kerf and the fact that factory board ends often need to be trimmed square, you will only get three 24" runners out of an 8-foot board, not four. You will get 39 runners out of these 13 boards.

• The Spacers: Cut the two 8.5" spacers from the scrap of the leg boards.

Shopping List Recommendation

Go with Option 1 (23 ten-foot boards) if you have a vehicle that can transport them. It results in fewer cuts, less overall waste, and prevents you from having to sort between two different lengths of lumber while you are building the rack.

Note: It is always a good idea to buy 1 or 2 extra boards just in case of a bad cut or finding a warped board in your pile!