Step 1

kitchen cart cut legs

kitchen cart cut legs

Marc uses a DeWalt tool to cut the legs for this kitchen cart furniture construction project.

Cut Legs

Take the 4x4 cedar posts and use a miter saw to cut them into four 29-inch pieces. These will be the four legs of the cart.

Step 2

kitchen cart position legs

kitchen cart position legs

Marc positions the wood legs on the kitchen cart construction project.

Position Legs on Plywood

Grab the piece of 1/2” thick plywood to act as the top of your cart and position the legs 1-1/2” in from each side. Trace the legs onto the plywood, so you know where to position them later.

Step 3

kitchen cart cut supports

kitchen cart cut supports

Cutting wood supports for this kitchen cart construction project.

Cut Supports for Legs

Measure and cut for supports to go between all four legs out of 2x2 cedar posts. These will be installed later.

Step 4

Reinforce Legs

Using the plank of cedar decking material, rip and cut the board down (Image 1), mitering the edges so that four pieces wrap the base of your legs, adding bulk so the cart won’t tip over (Image 2). Affix with glue and nails (Image 3).

Step 5

kitchen cart attach supports

kitchen cart attach supports

Marc uses a drill to attach wood supports to the kitchen cart frame in this furniture construction project.

Attach Supports to Legs

Screw the supports into the legs, countersinking the screws into each leg. Make sure to stagger the supports, so that the screws for each support don’t hit one another.

Step 6

kitchen cart attach legs

kitchen cart attach legs

Marc uses a drill to attach the legs to the kitchen cart frame.

Fasten Legs to Plywood

Attach the legs to the plywood top with 5/8” coated screws.

Step 7

kitchen cart castors

kitchen cart castors

Closeup of kitchen casters wheels being added to the feet of this kitchen cart furniture construction project.

Attach Casters to Legs

Attach four casters using 12-gauge screws, one to the bottom of each leg. Using two locking and two non-locking casters will keep your cart stationary while cutting.

Step 8

kitchen cart center support

kitchen cart center support

Marc uses a drill to attach the wood supports in this kitchen cart furniture construction project.

Add Center Support

Cut another 2x2 cedar baluster to use as a center support. This will line up with the two higher side supports and rest on the two lower side supports. Secure it to the lower side supports with glue and 2-inch screws.

Step 9

kitchen cart add slats

kitchen cart add slats

Marc uses nailgun to attach wood slats to kitchen cart frame in this furniture construction project.

Cut and Attach Slats

Rip additional 2x2 cedar balusters in half to use as slats for a shelf. How many you’ll make will depend on the size of your cart. Glue and pin nail these slats to your center and side supports.

Step 10

Affix Cutting Surface

Glue the surface of your cart perfectly in the center of the plywood (Image 1). This cart was made using a recycled piece of an old countertop, but you can also use butcher block or even an old cutting board (Image 2).

Step 11

kitchen cart frame

kitchen cart frame

Kitchen cart frame

Frame Cutting Surface

Again, take 2x2 cedar posts and miter the edges so they wrap perfectly around your cart surface, effectively “picture framing” it. Glue, nail and screw these posts onto the plywood, helping to lock the cart surface into place.

Step 12

Finish Cart

Fill in all nail and screw holes (the larger, countersunk holes with dowels), sand all wood surfaces, and rub the cart down with tung oil (Image 1). Finish the cart by running a silicone bead between the cart surface and the 2x2 wood that is picture framing it (Image 2). This will stop any oils or spills from getting beneath the surface and ruining your cart.