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CartHere’s How to DIY an Outdoor Kitchen
Create an outdoor kitchen and suddenly your living space expands and you feel like you’ve lucked into a summer vacation home! So, let’s get going. Great looks combined with weather-resistant durability are the secret to beloved outdoor kitchens and entertaining spaces. This DIY project keeps that in mind: simple-to-build cabinets with concrete countertops. The look: rustic and sophisticated, and tailormade for all of your al fresco get-togethers.
Supplies
1" Melamine MDF boards
Pressure Treated fence boards
Pressure Treated 2x2"
Pressure Treated 4x4"
acrylic caulking
Quikrete Countertop Mix Concrete
portland cement
wire mesh
wood screws
concrete and masonry sealer
Tools
hammer drill
impact driver
caulking gun
cement mixing paddle
utility pail
large sponge
drop cloth
plastic cover
insulated lined utility gloves
putty knife
safety glasses
Steps
1. Assemble all the materials and tools for your project.
2. Measure your site and measure the appliances you want to incorporate into your outdoor kitchen space – mini fridge, barbecue etc. This will allow you to determine the dimensions of your cabinets and countertops.
3. Sketch your cabinet plan to include all measurements. We went with a countertop depth of 25 inches and cabinet height of 36 inches, which includes a 2-inch countertop.
Part 1: The Cabinets
4. Measure, mark and cut your 4x4" pieces to form the corner posts for each cabinet. Next, cut the 2x2" pieces to your cabinet’s determined height.
5. For the unit that will house shelves, measure and cut the 2x2"s shorter. Leave space where a bottom shelf will sit and a gap where a middle shelf will sit.
6. Attach the 2x2"s to the 4x4"s using wood screws; these provide a framework into which you’ll attach your wood-panel siding.
7. For the back posts of each cabinet, attach an additional 2x2" piece lengthwise to an adjacent side of each 4x4" piece using wood screws.
8. The two 4x4" posts on the open front of your cabinet will have a 2x2” piece on only one side.
9. For a cabinet with two shelves, measure and cut eight 2x2" pieces to form support frames for your interior shelving.
10. Stand each cabinet post upright and then position each shelving support into place; fit each frame neatly into gaps. Secure all pieces with wood screws.
11. Measure and cut fence boards for the two sides and back of your cabinet. Screw horizontal fence boards into place, into the 2x2"s. Start at the bottom and work upward. Maintain equal distance between each board using a shim.
12. Repeat until the full side is complete. Repeat for the other side and back. Keep the front of the cabinet open.
13. Measure and cut fence boards to form your cabinet shelves. Lay the boards to form your shelf, again making sure they are equal distance apart. Attach boards to supporting shelf frame with wood screws.
14. Measure and cut four lengths of fence board to form the base of each cabinet countertop. Cut boards at a 45° angle to form mitred corners.
15. Screw countertop base onto the top of your cabinet frame at each 4x4" corner post. Ensure level.
Part 2: The Concrete Countertops
16. First, you need to create a mould for your concrete countertop(s) from Melamine MDF boards. Remember: When creating your mould, make sure that the interior dimensions of your mould correspond with the final dimensions of your finished countertop.
17. Next, measure, mark and cut the Melamine boards using a circular saw to form the sides and base of the mould. You will need four 2 5/8" strips for each mould.
18. Attach the Melamine MDF strips to the base of your mould using a drill and wood screws.
19. Seal the inside of your mould by running a bead of acrylic caulking along all seams. Smooth out the bead with a caulking tool or your finger. Let dry 24 hours.
20. Mix the concrete according to package instructions. With your countertop mould sitting on level surface, pour a half layer of prepared concrete into your countertop mould.
21. Wearing rubber gloves, smooth out the surface of the concrete, and shake mould to level.
22. Position a piece of wire mesh to cover the entire surface. This will strengthen your finished countertop. Add more prepared concrete to fill the mould.
23. Smooth the surface. You can use a piece of 2x2" to do so, making sure the surface is completely level. Bang or shake the mould, and run an orbital sander along the sides of the mould for 15 minutes. The vibration of the sander eliminates any air bubbles.
24. Cover wet concrete with plastic and leave to set undisturbed for 72 hours. If working outside, ensure that countertop is covered and protected. If you do not cover with plastic, the concrete will crack.
25. After 72 hours, remove plastic cover to reveal dry concrete. This is the underside of your countertop. Remove the sides of the mould, and with two people, flip your countertop. Now remove the base of the mould to reveal what will be your countertop surface. Because concrete is very porous there will inevitably be some holes. Make a paste using portland cement and fill any holes on the surface, edges and sides. Let dry.
26. Once the cement is dry, lightly sand and wipe clean.
27. Apply concrete sealer to the top and sides of the countertop using a roller and continue until the surface is saturated and will not absorb any more liquid. Let dry according to sealer instructions.
28. Position your concrete countertop on your cabinet. This is a two-person task as these countertops are very heavy!
29. Once in position, wipe your countertop clean, and accessorize your kitchen with all of the essentials for open-air cooking and entertaining. Now, you’re ready to make every outdoor moment amazing!
