Elevate your tableside service at the next family barbecue with this easy-to-make cart.
Time A day
ComplexityBeginner
Cost$150
Introduction
If your backyard is like mine, the grill isn't next to the table where we eat. A outdoor dining cart is the perfect way to bridge the gap.
Made from 2x2s and 1x6 lumber, this cart can be built in a day. Because it will spend most of its life outside, it's important to choose the right type of wood. Cedar is great because it's naturally rot resistant and looks terrific with an outdoor finish. Plus, it's readily available at any home store in the sizes called for here.
For the top, you can make your own or do what I did — find a local supplier of butcher block cutting boards and order one to the appropriate size.
With room for utensils, condiments, plus all your food, this outdoor dining cart will serve you and your guests for years to come.
Cutting List
| KEY | QTY. | PART | DIMENSIONS |
| A | 1 | Butcher Block Top | 28″ x 16″ x 1-1/2″ |
| B | 4 | Leg Post | 26″ x 1-1/2″ x 1-1/2″ |
| C | 4 | Leg Foot | 4″ x 1-1/2″ x 1-1/2″ |
| D | 2 | Crossmember | 10″ x 1-1/2″ x 1-1/2″ |
| E | 6 | Cladding – Side | 13″ x 5-1/2″ x 3/4″ |
| F | 6 | Cladding – Back/Drawer Face | 22-1/4″ x 5-1/2″ x 3/4″ |
| G | 4 | Drawer Support | 13″ x 2″ x 3/4″ |
| H | 2 | Drawer Side – Upper | 13″ x 3″ x 3/4″ |
| J | 2 | Drawer Front/Back – Upper | 16-1/4″ x 3″ x 3/4″ |
| K | 2 | Drawer Side – Lower | 13″ x 4 3/4″ x 3/4″ |
| L | 2 | Drawer Front/Back – Lower | 16-1/4″ x 4 3/4″ x 3/4″ |
| M | 4 | Drawer Bottom A | 17-3/4″ x 5-1/2″ x 3/4″ |
| N | 2 | Drawer Bottom B | 17-3/4″ x 2″ x 3/4″ |
| P | 2 | Drawer Stop | 3″ x 3/4″ x 3/4″ |
Tools Required
- 100 to 220-grit sandpaper
- Cordless drill
- Miter saw
- palm sander
- Table saw
Materials Required
- (16) 1" button head screws
- (2) 8' 2x2 cedar lumber (or equivalent)
- (4) 3/4" fender washers
- (5) 8' 1x6 cedar lumber
- #8 1-1/2" stainless steel screws (box)
- #8 2-1/2" stainless steel screws (box)
- 24" x 16" butcher block top
Project step-by-step (13)
Step 1
Cut the parts
- Most parts need to be cut to length on the miter saw.
- Cut the drawer parts to width on the table saw.
Step 2
Make the legs
- Cut four feet (C) with a 45-degree cut on one end.
- Attach the foot to the bottom of the leg (B) with 2-1/2-inch stainless steel screws.
Step 3
Make the side assemblies
- Screw the legs to the crossmember (D) using 2-1/2-inch screws.
- Place the drawer supports (G) using 1-1/2-inch screws.
Step 4
Clad the sides
- Attach the cladding (E) to the side assemblies using 1-1/2-inch screws.
- Hold the top course down from the top of the leg assembly by 1/8-inch and leave a 1/8-inch gap between the cladding.
Step 5
Assemble the base
- Complete the base by attaching the back cladding (F) to the two legs assemblies.
- Pro tip: For a super-clean look, try your hand at mitering the corners of the cladding instead of using butt joints.
Step 6
Make the drawers
- The drawers are made from the same 1×6 lumber as the cladding.
- Cut the sides (H and K) and the front/back (J and L) to length, then rip them to width on the table saw.
- Assemble the drawer boxes with 1-1/2-inch screws.
Step 7
Attach the drawer bottoms
- Cut the drawer bottom parts (M and N) to length, then rip Part N to width.
- Attach them to the drawer box with 1-1/2-inch screws.
Step 8
Attach the drawer stops
- This drawer stop keeps the drawer from tipping forward if pulled out too far.
- Cut four drawer stops (P) as shown and attach them to the bottom of the drawer using 1-1/2-inch screws.
- Sink a 1-1/2-inch screw into the drawer supports 3/8-inches from the top and about two inches from the front edge. Leave it sticking out about 1/2-inch. This will catch the drawer stop and keep it from tipping.
Step 9
Prepare the crossmember
- Drill two 1/4-inch holes in the crossmember. This is where you place the screws to secure the top in the next step.
Step 10
Place the top
- Place the top face down on your work surface and set the cart frame on it.
- Adding a washer, drive 2-1/2-inch screws through the crossmember into the top.
- Pro tip: You’ll notice the holes seem too big for the screws. This is on purpose. It allows the top to shrink and swell with the seasons without splitting.
Step 11
Attach the drawer faces
- Align the drawer faces with the cladding on the sides and attach them with 1-1/2-inch screws.
- I chose the clean look of no drawer pulls but you can add any type of pull that suits your style.
Step 12
Sand and finish
- Sand the entire cart with a palm sander. Start at 100-grit and stop at 220-grit.
- Apply a finish suitable for outdoor use, like clear spar varnish or oil-based exterior paint.
Step 13
Install the wheels
- With the cart flipped upside down, attach casters to the bottom of the legs with the screws provided.
