Introduction
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 1
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 2
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 3
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 4
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 5
Fasten Legs to Plywood
Attach the legs to the plywood top with 5/8” coated screws.
Step 6
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 7
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 8
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 9
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 10
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 11
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.
