DIY Square Breakfast Tray

Instructions

1. 1. Assemble Bottom of Tray

   Cut two pieces of 1x8 to 14 ½” long. Using a Kreg Pocket Hole Jig, drill ¾” pocket holes along the long edge of one of the boards. Using wood glue and 1 ¼” pocket hole screws, attach the boards together like shown to make a square.

2. 2. Cut Tray Sides

   Cut tray sides to fit around this square according to the cut list.

3. 3. Make Handles

   Using 1/8” thick x ¾” wide x 24”ish long steel flat stock, make tray handles as follows. Find the center of the steel bar and measure 3” out from each sides and mark. Bend bar along these lines about 45 degrees. Flip handle over and measure out about 1 1/4” from these bends and bend the opposite direction another 45 degrees to make two handles like shown. See video linked in extras tab for more details.

4. 4. Cut Out Tray Sides

   Center the handle like shown and trace the shape along the SHORT tray side pieces. Cut along this traced line with a jig saw to match the tray handle shape.

5. 5. Drill Pocket Holes for Assembly

   Drill ¾” pocket holes along the edges of the bottom side of the bottom square and drill one pocket hole in each end of the cut out tray sides in the top like shown.

6. 6. Assemble Tray

   Assemble the tray sides around the bottom and attach using 1 ¼” pocket hole screws.

7. 7. Assemble Tray Sides

   Once all pieces are attached along the bottom, attach at the top through the holes in the cut out pieces.

8. 8. Finish the Handles

   • Set handles on tray and mark where to trim so that they will be flush to the edges.
   • Trim steel using a steel blade in your circular saw, or a hacksaw.
   • Then, drill two holes in each side of each handle just large enough for a 1” wood screw to fit through.
   • Once holes are drilled, apply spray paint as desired. I painted mine with rose gold spray paint.

9. 9. Finish Tray

   Finish tray as desired with paint, stain, or wood finish of your choosing (I used beeswax because I like the natural wood color, but just wanted a little protection).

10. 10. Attach Handles

    Once the spray paint on the handles is dry, attach them in place using 1” wood screws through the holes you drilled earlier.