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HOW TO BUILD A BARBEQUE CART MATERIALS LIST

2. 2 shelves 3/4 inch x 14-1/2 inches x 48 inches plywood

3. 2 top frame rails 3/4 inch x 2-1/2 inches x 49-1/2 inches pine

4. 2 top frame stiles 3/4 inch x 2-1/2 inches x 16 inches pine

5. 2 bottom frame rails 3/4 inch x 2-1/2 inches x 48 inches pine

6. 2 bottom frame stiles 3/4 inch x 2-1/2 inches x 14-1/2 inches pine

7. 2 side panels 3/8 inch x 22-1/2 inches x 34-3/4 inches plywood

8. 2 spaces 3/8 inch x 1 inch x 22-1/2 inches plywood

9. 1 tool rack 3/8 inch x 2-1/2 inches x 18 inches plywood

10. 4 lengths of 3.8-inch dowel rod 2 inches long

11. 1 rest 1-1/2 inches x 5-1/2 inches x 14-1/2 inches pine

12. 4 legs 3/4 inch x 2-1/2 inches x 32-3/4 inches pine

13. 2 axle supports 1-1/2 inches x 3-1/2 inches x 4-1/2 inches pine

14. 2 wheels 4 inches in diameter by 1-1/2 inches thick

15. 1 axle made of 3/4-inch birch dowel rod 19 inches long

16. 2 handles 3/4 inch x 1-1/2 inches x 8 inches pine

17. 1 handle rod made of 3/4-inch birch dowel rod 14-1/2 inches long

18. 6 ceramic tiles 1/2 inch x 8 inches x 8 inches

19. Tile adhesive

20. No. 8 flat head wood screws 2 inches long

21. No. 8 flat head wood screws 1-1/4 inches long

22. No. 6 flat head wood screws 1 inch long

23. 1-inch brads

24. 6d finishing nails

25. 3/8-inch lag bolts 2 inches long

Construct the top frame by drilling pilot holes in the sides of the top rails and attaching them to the top stiles (Items 3 and 4) with No. 8 flat head wood screws 2 inches long. Construct the bottom frame from the bottom rails and stiles (Items 5 and 6) in the same way.

Attach the legs (Item 12) to the four corners of the top frame, driving No. 8 screws 1-1/4-inches long through the legs into the inside of the frame. The top of the legs should be 1-1/4 inches from the top of the rail.

Use No. 8 wood screws 1-1/4 inches to attach the legs to the bottom frame by fitting the bottom frame inside the legs.

Cut the axle supports (Item 13) and drill a 1-1/4 inch diameter hole 1/2 inch from the bottom edge.

Fit the axle supports into place along the front of the cart just behind the front legs. Attach the axle supports to the bottom frames with No. 8 flat head wood screws 2 inches long.

Cut the rest (Item 11) and attach it to the bottom frame 4 inches from the rear edge of the frame with No. 8 wood screws.

Attach the spacers (Item 8) to the bottom left edges of the top rail with 1-inch brads. Attach the side panels (Item 7) to the spacers with No. 6 flat head wood screws 1 inch long. The top of the side panels should be 1-1/4 inch below the top of the top frame. Then attach the side panels to the bottom frame with No. 6 wood screws.

Fit the bottom shelf (Item 2) into place over the bottom frame and attach it with 1-inch brads.

Turn the cart on its side. Fit the second shelf (Item 2) between the legs 8 inches below the top frame. Nail into place with 6d finishing nails.

Drill holes in the two handles (Item 16) to accommodate the handle rod (Item 17). Glue the rod in place and let dry. When dry, attach the handles to the back legs just below the top frame using 3/8-inch lag bolts 2 inches long.

Fit the top (Item 1) in place. Drive 6d finishing nails through the top frame to hold it in place.

Spread tile adhesive over the front end of the top covering a 16-inch x 24-inch area. Fit the tiles into place. Wipe up any excess adhesive.

Cut the wheels on a band saw from 2x6 pine stock. Drill a hole 3/4 inch in diameter in the middle of each wheel. Or you can purchase ready-made wheels at your local home center.

Slip the axle rod (Item 15) into place between the axle supports (Item 15) into place between the axle supports (Item 13). Smear the ends of the rod with glue and fit the wheels onto each end. Let dry.

Drill four 3/8-inch diameter holes in the tool rack (Item 9). Smear the ends of the dowel rods (Item 10) with glue and insert them into the rack. Let dry.

When dry, attach the rack to the side left panel with No. 6 wood screws.

Make sure all the glue and tile adhesive has dried. Use a nail set to drive the nail heads below the surface of the wood. Fill the holes with wood putty. When the putty is dry, sand the entire cart, stain the cart with mahogany stain, and paint with polyurethane varnish to seal.