Easy Build Grill Cart - DIY Guy

This week, we built a fast, easy, grill cart for the back deck.

The best part is, we built it using inexpensive, preassembled crates from Lowe's.

Also, we grilled burgers afterward, which is always good.

This video gives an in-depth, step-by-step description of our build.

Anything you don't find here in the Instructable, you'll find in the video.

You'll need the following:

(3) Wooden Crates

(1) 2-1/2"x 3-1/4" Pine Board

A board for the top (your choice ... pick something pretty)

(4) Casters

Minwax Polyshades Stain (Mission Oak)

Tools

Miter Saw

Jig Saw

Table Saw (or have Lowe's cut your top for you)

Drill/Driver

Kreg Pocket Hole Jig

Some clamps are handy too.

Cut your pine board down to 3-1/2 inch blocks.

If you want to put a top on your cart like we did, you'll need 12 of these blocks

Drill two pilot holes in each block.

Set aside 4 blocks. These blocks will go on the top crate, and attach to the top.

For these 4, you'll also need to drill a pocket hole in the center.

That way, when you attach the top to the cart, the screws are hidden.

Glue and screw one in each corner.

Do this for all three crates.

Remember to put all the blocks with the pocket holes on the same crate.

Cut the rest of your pine board into two strips, 11-3/4" long.

Go ahead and mount these to the bottom crate with screws and glue.

This is what we'll use to attach the wheels for the cart.

Measure 1-1/5" in from the sides of your crates, and cut out the top three slats on one side with a jig saw.

We cut a board down to 15" x 20" for our top.

There are a bunch of options for stain, but we used a simple spray-on stain with included protective finish.

Make sure to completely and evenly cover all surfaces.

Drill holes for your wheels on the bottom crate. We used locking casters, but you can use whatever strikes your fancy.

Secure those suckers with locking nuts.

Make sure if you have locking wheels, you mount them both on the same side of the crate, otherwise they won't work.

Stack your crates and line them up.

The crate with the wheels goes on the bottom (obviously)...

and the crate with the pocket holes goes on the top.

Fasten these together with screws through the blocks we attached earlier. (Pre-drilled pilot holes help)

Screw it on using the pocket holes you drilled earlier, and you're done.

Just look at that thing, classing up your deck like a champ. Even E-dub, the DIY Dog loves it!

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