NotchLoading plan…
Loading plan…
Use your browser's Print (Ctrl/Cmd + P) and choose Save as PDF. This page works offline once you've opened it with a signal.
Create the perfect companion to your outdoor grill with this rolling cart.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Side Slat | 12 | 3/4" × 5" × 23" | — | ☐ |
| Vertical Rail | 4 | 3/4" × 1" × 33" | — | ☐ |
| Front Rail | 3 | 3/4" × 1" × 21" | — | ☐ |
| Back Rail | 3 | 3/4" × 3" × 21" | — | ☐ |
| Shelf Slat | 8 | 3/4" × 5" × 23" | — | ☐ |
| Top Frame | 4 | 3/4" × 1" × 27" | — | ☐ |
| Top Panel | 1 | 3/4" × 24" × 24" | — | ☐ |
| Top Sheet | 1 | 1/16" × 24" × 24" | — | ☐ |
| Caster Block | 4 | 3/4" × 3" × 3" | — | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Board, 1x6 96" | 5 board | ☐ |
| Board, 1x4 96" | 1 board | ☐ |
| Board, 1x2 96" | 4 board | ☐ |
| Plywood, 3/4" Thick 24" | 1 board | ☐ |
| 2" rubber swivel casters | 4 each | ☐ |
| 1/4" x 1 1/2" lag screws | 16 each | ☐ |
| 1-1/4" exterior-rated pocket-hole screws | 150 each | ☐ |
| Epoxy adhesive | 1 each | ☐ |
| 24" x 24" galvanized sheet metal | 1 each | ☐ |
Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.
cut twenty Slats to length from 1x6 boards, as shown in the cutting diagram. Some of these Slats will be used to make the sides of the grilling station, and others will be used to make the shelves, but they all start off the same length.
Tip: Set Up Stopblocks The best tool for cutting all the parts to size is a miter saw. To make cutting easier, set up a stop block so that you can cut all of your like-sized parts (such as the Slats) without having to measure each individual piece.
Using 12 of the slats you cut in Step 1, you can make the Side Slats. With your Kreg Jig set up for 3/4"-thick material, drill pocket holes in the ends of all 12, as shown. Then drill holes along one edge of two of these to create the Top Side Slats. These holes on the edge will be sued to attach the grilling station Top later.
Position the remaining Side Slats as shown so that there are equal gaps between all of the Slats. Then attach these Side Slats to the Vertical Rails using 1 1/4" Blue-Kote™ pocket-hole screws.
Tip: Proper Metal Prep Be sure to clean up your steel to remove any oil or residue that could prevent adhesive from sticking. To do that, first sand the underside of the metal sheet with medium-grit paper. Then use denatured alcohol and a rag to clean the metal sheet.
Next, attach the second side. Make sure that the assembly is square, and that the middle shelf will sit level.
Tip: Check for a Square Assembly As you bring the cart assembly together, check to make sure you have the second side assembly oriented correctly. Also make sure that everything is square, and that the shelves will sit level.
Lay the top assembly face down, then position the grilling station base on it making sure the top overhangs equally on all sides. Attach the base to the top assembly using 1 1/4" Blue-Kote™ pocket-hole screws.
Cut three Front Rails to length from a 1x4 board, and cut three Back Rails to length from a 1x4 board, as shown in the cutting diagram. With your Kreg Jig® set up for 3/4"-thick material, drill pocket holes where shown in the Front and Back Rails.