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Outfit Your Fire Pit

How to Make a Serving Cart With Removable Tray (page 1 of 2)

Learn how to make a beverage cart that can be taken from your kitchen straight to the great outdoors.

More in Outdoors

Here's How You'll Do It:

No need to worry about getting this cart out the door and through the yard. Its 6-inch lawnmower wheels can take it through thick grass or uneven terrain. And with a removable tray and spacious storage up top and on the bottom shelf, you'll be able to provide ample supplies to your outdoor event.

Look for cedar pieces that are straight and have the fewest knots, especially knots that are on the edge of the board. Note that dimensional cedar (2x4s for example) may be more difficult to find at your local home improvement center or hardware store, so you may need to visit a lumber yard.

In any woodworking project, it's typically best to cut all parts as you need them and not all at once. One small error can ruin an entire stack of lumber. This project uses pocket hole joinery in a few instances.

Project Cut List

For the Cart:

Legs -- eight at 1-1/2" x 3-1/2" x 31-3/4"
Wheel Blocks -- four at 3/4" x 3-1/2" x 3"
Bottom End Rails -- two at 3/4" x 3-1/2" x 22"
Top End Rails -- two at 3/4" x 3-1/2" x 18"
Bottom Side Rails -- two at 3/4" x 3-1/2" x 28-1/2"
Top Side Rails -- two at 3/4" x 3-1/2" x 23"
Bottom Stretcher -- one at 3/4" x 3-1/2" x 20-1/2"
Outer Bottom Slats -- two at 3/4" x 5-1/2" x 30"
Inner Bottom Slats -- three at 3/4" x 3-1/2" x 30"
Storage End Rails -- two at 3/4" x 3-1/2" x 22"
Storage Side Rails -- three at 3/4" x 3-1/2" x 28-1/2"
Storage Stretcher -- one at 3/4" x 3-1/2" x 15"
Tray Stop -- one at 3/4" x 5-1/2" x 15"
Long Shelf -- one at 3/4" x 3-1/2" x 28-1/2"
Short Shelf -- one at 3/4 x 3 1/2 x 15
Handle Blocks -- four at 1-1/2" x 3-1/2" x 3-1/2"
Handles -- two at 1" x 21-1/2"

For the Tray:

Tray Ends -- two at 3/4" x 4-3/4" x 14-1/2"
Tray Bottom -- one at 3/4" x 14-1/2" x 22-1/8"
Tray Sides -- two at 3/4" x 3-1/4" x 23-5/8"

Build the Leg Assemblies

Use the layout (image 1) as a guide for drilling pocket holes in four legs. Attach the legs with the pocket holes to the remaining legs using glue and 2-1/2" pocket-hole screws (image 2).

Attach the wheel blocks to the bottom of the legs using glue and 1-5/8" deck screws (images 3 and 4).

Drill a 1/2" axle hole in the ends of the leg assemblies. You'll insert the axle in a later step.

Apply the finish to the leg assemblies. We used Cabot Solid Color Acrylic Siding Stain (Evergreen) on the legs because it acts as a primer/sealer and top coat in one.

Build the Rail Assemblies

Use the layout (image 1) as a guide for drilling pocket holes in the bottom end rails, top end rails, bottom side rails, and top side rails. Apply a finish to the rails. We used Cabot Solid Color Acrylic Siding Stain (Redwood).

Position the bottom end rails flush against the top edge of the wheel blocks and attach using glue and 1-1/4" pocket-hole screws (image 2).

Position the top end rails 1/4 inch from the top and flush with the inside edge of the leg assemblies and attach using glue and 1 1/4" pocket-hole screws (image 3). Use a piece of 1x stock (3/4-inches thick) as a spacer to position the rails flush with the inside edge.

Position the bottom side rails flush against the bottom end rails on one end assembly (image 4) and attach using glue and 1-1/4" pocket-hole screws (image 5).

Position the top side rails 1/4 inch from the top and flush with the inside edge of the leg assemblies and attach using glue and 1-1/4" pocket-hole screws (image 6). Use a piece of 1x stock (3/4-inches thick) as a spacer to position the rails flush with the inside edge.

Attach this assembly to the other end assembly using glue and 1-1/4" pocket-hole screws.

Build the Bottom Shelf

Use the layout (image 1) as a guide for drilling pocket holes in the bottom stretcher. Test fit, remove and apply sealer. We used Olympic Maximum Sealer (Clear). Allow to dry.

Position the bottom stretcher (image 2) and attach using glue and 1-1/4" pocket-hole screws (image 3). Test fit the outer bottom slats and the inner bottom slats. Remove and apply clear sealer and allow to dry.

Place the assembly on one end and position the outer bottom slats (image 4) and attach using 1-1/4" pocket-hole screws (image 5).

Position the inner bottom slats flush with the ends and equidistantly spaced between the outer bottom slats and attach using 1-1/4" pocket-hole screws (image 6).

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