I spent some time this summer (more than I’d care to admit) working on a grill cart for my Weber kettle. The goal was to create more work space for handling food going on and off the grill and to have some outdoor storage for fuel and utensils. As a beginner learned a lot of woodworking techniques along the way. Thank you YouTube!
The finished product.
I started by cutting down some cedar 4x4s to be smaller and to act as the corners.
I used pocket hole joinery for much of the structure.
The ends of the cart were added to 2×4 cross boards to form the cabinet. I worked on sawhorses to make life a little easier.
Added more 2x4s between the front and back to divide the cart’s open-air side and the enclosed side. I also added a vertical 2×4 on the face and a horizontal 1×1 to separate the drawer and cabinet doors.
I created paneling from cheap cedar fencing and added chamfered edges. These were screwed in from the inside leaving enough room for a cleat that I’d add later below the panels.
Here’s the cleat on the open-air side and the floor going in. I used 1x4s and added a small gap between the boards.
Edge-glued some boards together for the cabinet doors
Pocket holes for the drawer with 1/8 plywood for the bottom. I later used 2 sided tape to hold the drawer front on while I screwed it in and added the pull.
I put spacers inside of the cabinet to get the drawer slides to line up correctly with the opening.
I got my hardware from a few different places including our local Habitat for Humanity ReStore. I used a black metallic spray paint to make it all match.
This is the drawer front getting some tung oil. I had also routed the edges with a roundover bit.
The whole cart got several coats of tung oil. I used Real Milk Paint’s tung oil with citrus solvent. I used this oil to give it some protection outside without having to worry about a solid film flaking off. The citrus solvent helps it absorb into the wood while remaining safe for food contact.
I added a slot along the top for tabletop fasteners. I used a router with a slot cutting bit.
The table top was made from 5/4 cedar decking. The boards were edge joined with pocket holes and glue.
Part of the glue up. The pocket screws helped keep the boards relatively flat to each other despite being very warped.
Cut the ends of the table top with a circular saw and then added a roundover edge with the router.
I made a simple circle-cutting jig with some scrap plywood and nailed it to the bottom of the tabletop.
To make the grill fit I sawed off the handles.
The lip of the grill hangs on 8 conduit straps mounted to the underside of the tabletop.
Time to add the cabinet to the upside down tabletop.
The tabletop fasteners are there to allow for wood movement.
Casters, doors and pulls added. The grill cart is ready for action!