Rolling Kitchen Cart

Instructions

1. 1Make the Legs

   Cut four Legs to size from a 2x2 board, as shown in the cutting diagram.

2. 2Make the Upper End Rails

   Cut two Upper End Rails to length from 1x3 boards, as shown in the cutting diagram. Then, with your pocket-hole jig set up for 3/4" material, drill pocket holes in the Upper End Rails, as shown.

   

3. 3Make the Middle End Rails

   Cut two Middle End Rails to length from 1x2 boards, as shown in the cutting diagram. Then, with your pocket-hole jig set up for 3/4" material, drill pocket holes in the Middle End Rails, as shown.

   

4. 4Make a Lower Closed End Rail

   Cut one Lower Closed End Rail to length from a 1x3 board, as shown in the cutting diagram. With your pocket-hole jig set up for 3/4" material, drill pocket holes in the Lower Closed End Rail, as shown.

   

5. 5Make an End Panel

   • Cut one End Panel to size from 3/4" plywood, as shown in the cutting diagram. With your pocket-hole jig set up for 3/4" material, drill pocket holes in the End Panel, as shown.
   • Next, drill stopped holes where shown to hold shelf pins. The easiest way to do this is with a shelf pin jig (we used one made by Kreg). A shelf pin jig makes it easy to drill consistently spaced holes so your shelf will sit level and not wobble.

   

6. 6Assemble the Closed End

   • Now you can assemble the closed end of the cart. To make this easy, start by attaching the Lower Closed End Rail and the Middle End Rail to the End Panel using 1 1/4" coarse-thread pocket hole screws.
   • Then attach this assembly and the Upper End Rail to two of the Legs, as shown. Note that all of these pieces fit flush with the inside faces of the Legs.

   

7. 7Make a Lower Open End Rail

   Cut one Lower Open End Rail to length from a 1x3 board, as shown in the cutting diagram. With your pocket-hole jig set up for 3/4" material, drill pocket holes in the Lower Open End Rail, as shown.

   

8. 8Assemble the Open End

   Now you can assemble the open end of the cart. To do that, attach the Lower Open End Rail, Middle End Rail, and Upper End Rail to the other two Legs using 1 1/4" coarse-thread pocket hole screws. Note that, once again, all of these pieces fit flush with the inside faces of the Legs.

   

9. 9Make the Side Rails

   Cut two Side Rails to length from 1x3 boards, as shown in the cutting diagram. Then, with your pocket-hole jig set up for 3/4" material, drill pocket holes in all four Side Rails, as shown.

   

10. 10Make an Upper Stretcher

    Cut an Upper Stretcher to length from a1x3 board, as shown in the cutting diagram. With your pocket-hole jig set up for 3/4" material, drill pocket holes in the Upper Stretcher, as shown.

    

11. 11Make a Lower Stretcher

    Cut one Lower Stretcher to length, as well, and then drill pocket holes, as shown. This stretcher gets extra holes that will be used to help secure the Slats later.

    

12. 12Create an Upper Assembly

    Attach the Upper Stretcher to two of the Side Rails, as shown, using 1 1/4" coarse-thread pocket hole screws. Make sure that all of the pocket holes are oriented in the correct direction.

    

13. 13Create a Lower Assembly

    Attach the Lower Stretcher to the other two Side Rails, as shown, using 1 1/4" coarse-thread pocket hole screws. Make sure that all of the pocket holes are oriented in the correct direction.

    

14. 14Make the Slats

    • Cut two Outer Slats to length from 1x3 boards, as shown in the cutting diagram.
    • Then cut six Inner Slats. They’re longer than the Outer Slats. Plus, you’’ll need to drill pocket holes in one end of each Inner Slat, as shown. These will allow the Inner Slats to be attached to the closed end of the cart later.

    

15. 15Attach the Slats

    • Now you can attach the Slats to the lower rail/stretcher assembly using 1 1/4" coarse-thread pocket hole screws, as shown. The best way is to first attach the Outer Slats to the Side Rails, making sure they’re flush at both ends.
    • Then add the Inner Slats, spacing them evenly and attaching them to the Lower Stretcher. They’ll each just be held on with one screw for now, but that’s ok.

    

16. 16Start Base Assembly

    • Attach the structure of Slats you just created, as well as the upper rail/stretcher assembly to the closed end of the cart.
    • First attach the Side Rails to the Legs using 1 1/4" coarse-thread pocket hole screws, as shown.
    • Then attach the Slats to the End Panel.

    

17. 17Attach the Other End

    Now you can attach open end assembly by screwing the Side Rails to the Legs using 1 1/4" coarse-thread pocket hole screws, as shown.

    

18. 18Cut the Top Parts

    • Cut the Top to size from 3/4" plywood, as shown in the cutting diagram. With your pocket hole jig set up for 3/4" material, drill pocket holes the underside of the Top where shown.
    • Then cut two pieces of Long Top Edging and two pieces of Short Top Edging to length from 1x2 boards, as shown in the cutting diagram.

    

19. 19Add the Top Edging

    • Next, attach the edging to the top using 1 1/4" coarse-thread pocket hole screws, as shown.
    • First, attach the Short Top Edging, making sure the ends fit flush with the edges of the Top.
    • Then attach the Long Top Edging.

    

20. 20Dress Up the Top

    With the edging installed, the top has sharp corners. So, you can ease those corners around the perimeter of the top. If you have a router, use a 45° chamfer bit and ease the edge, as shown. If you don’t have a router, you can simply use sandpaper on a block.

    

21. 21Attach the Top

    Lay the top assembly face down, and then place the base assembly on it. Make sure the top overhangs equally on each end, and on each side, and then attach the top using 1 1/4" coarse-thread pocket hole screws, as shown.

    

22. 22Cut the Platform Parts

    • Cut a Platform to size from 3/4" plywood, as shown in the cutting diagram. With your pocket hole jig set up for 3/4" material, drill pocket holes the underside of the Platform where shown.
    • Then cut two pieces of Platform Edging to length from 1x2 boards, as shown in the cutting diagram.

    

23. 23Add the Platform Edging

    Next, attach the edging to the Platform using 1 1/4" coarse-thread pocket hole screws, as shown.

    

24. 24Attach the Platform

    Position the Platform in the base assembly, as shown, and then attach it using 1 1/4" coarse-thread pocket hole screws, as shown.

    

25. 25Make a Divider

    • Cut one Divider to size from 3/4" plywood, as shown in the cutting diagram. With your pocket-hole jig set up for 3/4" material, drill pocket holes in the End Panel, as shown.
    • Next, drill stopped holes where shown to hold shelf pins. Note that the shelf pin holes in the Divider are located 3/4" lower. That’s because the Divider will sit on top of the Slats when installed. Having the shelf pin holes lower makes means they’ll line up with the holes in the End Panel. With the divider done, also cut two pieces of Divider Edging and attach them using 1 1/4" coarse-thread pocket hole screws. Make sure the edging is flush with the lower edge of the Divider.

    

26. 26Attach the Divider

    Now you can slip the divider assembly into place, and then attach it to the Position the Platform in the base assembly, as shown, and then attach it to the Platform and to the Inner Slats using 1 1/4" coarse-thread pocket hole screws, as shown.

    

27. 27Create the Shelf

    • Cut a Shelf to size from 3/4" plywood, as shown in the cutting diagram. With your pocket hole jig set up for 3/4" material, drill pocket holes the underside of the Shelf where shown.
    • Then cut two pieces of Shelf Edging to length from 1x2 boards, and attach the edging to the Shelf using 1 1/4" coarse-thread pocket hole screws.

    

28. 28Add Casters and Finish

    • To complete the cart, add swivel casters to the bottom of each Leg.
    • Then slip the shelf into place on shelf pins to check the fit.
    • Sand your cart as needed, and then apply paint or stain—or both, as we did.