Loading plan…
Loading plan…
Step-by-step build — 8 steps. Also available as a print sheet.
Build the box from the ends and sides — a pocket hole jig set for 3/4" stock and 1-1/4" pocket screws works well, or nail and glue with 1-1/4" nails. Attach the plywood bottom with 3/4" brad nails or staples.
Attach the trim to the box with 1-1/4" brad nails and glue. Attach the umbrella pole dowel with 1-1/4" screws. Set this assembly aside.
Build the top awning piece with pocket holes (preferred) or nails and glue. Attach its support dowel with screws.
Attach the awning assembly to the 2x2 legs with 2-3/4" wood screws.
Attach the 2x2 legs to the box with 2-3/4" screws driven from inside. Set the assembly aside.
Build the wheel-support assembly from the 1x4 pieces. Pocket holes are preferred, but 1-1/4" brad nails work too.
Clamp the wheels to the wheel-support system and check the whole cart sits level before drilling anything permanent. Drill through the center of each wheel into the support system and attach with bolts, washers, and nuts.
Hinge the 1x8 serving flaps to the 1x2 trim, checking that they swing clear of the wheels and legs before you finish tightening the hinges.