Here’s How to Make an Outdoor Grill Cart

Power Tools

Exterior Glue

Nails

Screws

Measuring Tape

Paint

Tile

Wood

BeautiTone Wood-Shield Advanced Protector

Step #1: Determine the Size of Your Cart

Start by determining the width, length, and height of your cart. Our cart is 24’’ x 36’’. Cut the plywood for the base and sides following the cut list below.

Step #2: Attach Support for Bottom and Wheels

Rim the base with 2’’ x 4’’; this will support the bottom and the wheels of the cart. Use exterior glue and 1 ¼’’ nails to secure.

Step #3: Attach Three Sides

Attach 3 sides of the cart leaving the door front open. Hide the base when attaching the sides.

Next, connect the 2 sides by positioning a piece of plywood backed off the front by ¾’’. Attach with screws. This will be the support for the door fronts.

Step #4: Cut Doors & Shelf

Measure and cut plywood for the doors and shelf. See the complete cut list below.

Step #5: Add Shelf Support

Attach 1’’ x 2’’ around the 3 sides as support for the shelf. Be sure to inset the side pieces ¾’’ from the door front. You may want to trim the front of the shelf to hide the raw edge.

Step #6: Paint all Surfaces

Paint all surfaces inside and out, even the bottom. Paint both sides of the doors as well. We used BeautiTone Exterior Paint in the colour Star-Studded (C21-1-0620-3).

Tip: Paint will add an extra layer of protection as well as a background colour once we add the decorative battens.

Step #7: Build the Top of the Grill Cart

Cut a piece of plywood to 25 ½’’ x 33 ½’’. Dry lay a membrane and tile onto the plywood. Frame the plywood with a 1’’ x 2’’ flush around it (allow room for the depth of the membrane, tile, and thin set). Attach the mitered frame with glue and nails.

Then, attach the top to the box with glue and screws. Secure around all four sides.

Step #8: Attach Battens & Doors

Attach 2 battens on either side of the open front, flush to the corners. Next, attach the doors to the inside frame with hinges. Build the remaining corners using the 1 x 2 battens. Once attached calculate the space between the corners and divide equally. Attach the battens all around, spacing out evenly along the sides, back, and doors.

Tip: Once you have determined the space, cut a spacer to use when attaching all the battens.

Step #9: Attach Caster Wheels

Carefully flip the cart over onto its side and attach the casters to the base with 1 ½’’ #12 screws. Lock the wheels before flipping it back.

Step #10: Tile the Top of your Grill Cart

Your cart is now ready for tiling. Use a notched trowel to apply a thin-set mortar to the plywood. Lay an uncoupling membrane on top. Add another layer of thin set. Position and press the tile pattern into place and let dry.

Apply grout in between the tiles and around the frame. Wipe the surface clean multiple times to remove all grout residue and haze.

Step #11: Seal Surface

Once everything is clean and dry. Fill any screw holes with wood filler, lightly sand and seal the entire wood surface with BeautiTone Wood-Shield Advanced Protector.

Step #12: Build Handles for Both Sides

Pick up a few galvanized pipe pieces and make a pull handle for the cart. We used the following components for the handle:

• 2 - ½’’x 3’’

• 2 - ½’’ 90° elbow

• 1 - ½’’ x 12’’

• 2 - ½’’ flange

Ensure the handle is clean, dry, and dull, and then spray paint it a colour of your choosing. Once dry, attach it to both sides. Attach magnetic latches to the inside frame and doors to complete.