illustrations by Vincent Morrelli
You have the grill, but everything that goes along with it needs a spot, from the tools to the charcoal briquets. This cart keeps all of those supplies together and within easy reach, since it’s on wheels. Bonus: When not using it for a cookout, put it to work as a handy utility cart around the yard.
1. CHOOSE THE WOOD
Avoid treated lumber, as it shouldn’t come into contact with food. Cedar will hold up better to the weather if the cart is left outside, but the lumber can be expensive. We also like the idea of choosing pine and painting it with an outdoor paint or sealant to protect it.
2. START WITH THE FRAMES
This cart consists of three frames built from 1x3s with a finished size of 24 inches by 29 inches. The countertop overhangs the top frame, the middle frame supports a shelf, and the bottom frame also has a shelf, with wheels attached underneath. Cut a 1×3 into six lengths measuring 22.5 inches and six lengths of 29 inches. Form three rectangular frames by placing the shorter pieces between the longer pieces and attaching with a butt joint and screws.
3. ATTACH THE SHELVES
The bottom two shelves consist of 1x4s equally spaced across the frame, with about a 1/8-inch gap between each board. There will be eight boards per shelf, each cut 24 inches long. Attach these to the frame so that they are flush.
4. MAKE THE TOP
Cut a 2×6 into five pieces, each 36 inches long. Sand them, and lay them out side-by-side so there’s a 1/8-inch gap between each board, for a finished size of 36 inches by 28 inches. Place the last frame atop this so that the counter will clear it by 2 to 3 inches when it’s flipped over. Attach the frame to the boards—if you do this from underneath, the hardware won’t be seen on the countertop for a cleaner look.
5. PREP THE METAL
Use 2-inch aluminum angle iron, each 36 inches long, for the four legs, one piece for each corner. Space the countertop and shelves equally, and mark their location on the iron. Pre-drill four holes per corner (two per face), and then attach the frames. Start with the bottom shelf, followed by the middle shelf and, finally, the countertop. (Note: Paint the metal first for a fun pop of color.) If adding a push handle using steel plumber’s pipe and connectors, prep those by cleaning with denatured alcohol and spray painting them a color of your choice.
6. FINISH AND ACCESSORIZE
Add caster wheels to the bottom frame. If desired, attach the push handle, which can double as a towel bar. Accessorize the apron under the counter with hooks for grill tools and a wall-mountable bottle opener. Seal the exposed wood with a food-safe finish of your choice. Now feast!
