Tabletop grill cart diy
This was one of those instant gratification building projects. It took me less than two hours to build and it solved my problem of not having a dedicated space for my tabletop grill. When we renovate our outdoor living space, we plan to upgrade our grill to something more substantial. In the meantime, I needed something to sit my grill on that didn’t take up too much space and was mobile.
I used Ana Whites Simple Rolling Bar Car plans and tweaked them to fit my grill.
The feet of the tabletop grill need 18″ of space front to back so I modified the end aprons and all the shelf slats by adding 4″ to the length. I also shortened the legs because I was using 4″ casters that I already had.
The supplies cost me less than $30 including the spray paint which cost $9 for three cans.
I drilled pocket holes into the ends of the front and back aprons to make two rectangular frames. Then I screwed and glued the legs to the frames using countersunk 2-1/2″ Spax screws.
It was imperative that this be 100% level. If it wobbled then the casters will never work properly.
I needed a towel bar and I didn’t like the pipes that Ana suggested in her plans so I built one using some scraps and a 1″ wooden dowel.
I first cut a piece of wood to 3″x4″. I cut the ends of the wood at a 45° angle then cut a 1/2″ off the pointy tip.
Next I took an inch off the bottom of the pieces.
Then I clamped the pieces together and sanded them as round as I could get them. My patience with my palm sander didn’t last very long so I settled on the shape below
While they were still clamped together, I drilled a tiny hole through both pieces. Then I flipped them over and drilled counter sink holes through one side of each piece.
I secured each piece and bore a 1/4″ deep hole through the opposite side of each piece with a 1″ Forstner Bit. I used the tiny hole as my center and I got perfect recesses. I cut the dowel to length and then glued and screwed the pieces and the rod together. When the glue dried, I screwed the bar to the cart from the inside.
I used a 1/4″ piece of plywood as a spacer and added my slats using glue and 2″ brad nails. I filled all the nail and screw holes with wood filler and sanded the surfaces smooth.
When it was time to prime, I used my tried and true Zinsser Cover Stain Oil Based primer. I primed the underside and bottom parts first. Then I flipped it over and primed the top and sides.
I repeated the same process with the spray paint only I gave the bottom two coats before flipping over. I sprayed between the slats before spraying the rest of the cart.
After 4 coats of Rustoleum Painters Touch 2x in Satin Paprika I let the cart dry overnight.
Since this will sit outdoors I used Minwax Spar Urethane in Satin finish to seal the paint. This is my first time using an oil based spar urethane so I don’t know how well it will protect. To be on the safe side, I followed the instructions on the can and applied 4 coats.
Amongst my collection of junk, I found this stainless steel “S” hook bar. I attached it to the opposite side of the cart for my utensils to hang on. I also added the casters to the bottom.
The size is perfect for my shabby deck. There’s enough room to hold the grill and somewhere to sit things down.
Before I could add my grill It needed some attention. I scrubbed it down with Bar Keepers Friend and removed the legs and handles.
The blue clashed with the new paprika colored cart so I hit it with the High Heat spray paint designed specifically for this type of application.
Now it looks much better.
And my tabletop grill now has a home.
This is the type of “Instant Gratification” that even Amazon cannot provide.