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A rolling counter-height cart with a slatted cedar top and full lower shelf, sized for a portable grill.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Legs | 4 | 3 1/2" × 3 1/2" × 23 3/4" | 4x4 | ☐ |
| Width aprons Adjustable — widen to fit your grill. | 4 | 1 1/2" × 3 1/2" × 21" | 2x4 | ☐ |
| Length aprons Adjustable — shorten to fit your space. | 4 | 1 1/2" × 3 1/2" × 65" | 2x4 | ☐ |
| Center supports | 4 | 1 1/2" × 3 1/2" × 24 1/2" | 2x4 | ☐ |
| Top and shelf slats | 10 | 5/8" × 5 1/2" × 72" | Cedar fence picket | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Construction lumber, 4x4, 8 ft The four legs. | 1 each | ☐ |
| Construction lumber, 2x4, 8 ft Frame and center supports. | 5 each | ☐ |
| Cedar fence pickets, 5-1/2" x 72" Top and shelf slats. | 10 each | ☐ |
| Pocket hole screws, 1-1/2" | 50 each | ☐ |
| Self-tapping exterior deck screws, 1-3/4" | 80 each | ☐ |
| Caster wheels, 5" total height | 4 each | ☐ |
| Exterior penetrating stain | 8 oz | ☐ |
Overall cost: $$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Circular Saw, Pocket Hole Jig. Materials: Construction lumber, 4x4, 8 ft, Construction lumber, 2x4, 8 ft
Cut the four 4x4 legs to 23-3/4" and drill pocket holes in both ends of every 2x4 piece.
Tools: Drill / Driver. Materials: Construction lumber, 4x4, 8 ft, Construction lumber, 2x4, 8 ft, Pocket hole screws, 1-1/2"
Join the short (21") width aprons between pairs of legs with pocket screws to build two identical end frames. This sets the cart's width — adjust this measurement now if your grill needs more or less room.
Tools: Drill / Driver. Materials: Construction lumber, 2x4, 8 ft, Pocket hole screws, 1-1/2"
Join the two end frames with the long (65") length aprons to form the full-length frame.
Tools: Drill / Driver. Materials: Construction lumber, 2x4, 8 ft, Pocket hole screws, 1-1/2"
Add the 2x4 center supports (24-1/2") across the frame — these are what carry the top and shelf slats, so space them to keep any gap between slats from sagging under a loaded platter.
Tools: Drill / Driver. Materials: Cedar fence pickets, 5-1/2" x 72", Self-tapping exterior deck screws, 1-3/4"
Cover the top and lower shelf openings with the cedar slats, spaced evenly with a consistent gap between each — the gap is what lets water drain and air circulate instead of pooling next to a hot grill.
Tools: Drill / Driver. Materials: Caster wheels, 5" total height, Exterior penetrating stain
Attach the four caster wheels to the bottom of the legs, then finish the whole cart with an exterior penetrating stain.
Use a heat-safe surface under the grill itself and follow the grill manufacturer's own clearance instructions — this cart is a prep surface, not a heat shield.