This is a great project for the myriad woodworkers who also enjoy outdoor grilling. The cart is designed with a large 18" x 24" inlaid cutting board, a slot for a condiment tray (the one seen here holds 6 1-pint dishwasher safe containers), a slot for knives, and runners for 2 stainless-steel pans.
I made a few modifications to my cart from the specs given in Popular Mechanics.
- Most notably is the addition of a side-mounted table, which I think is useful in freeing up space on the cutting board. I cut a notch in the bottom of the table and mounted a hinge on the second shelf of the cart to hold the side table level. When the table is not in use, the lever and table can swing down and attach to the leg of the cart with a simple hook and eye fastener.
- I used whitewood, instead of cedar, to cut down on cost. I then used a cherry stain and then coated it with a spar sealer to survive the elements.
- I added 3" to each of the legs. I found that the original height of the cart was too short and awkward to cut on for me (I'm about 5'11"). I would recommend finding the most comfortable cutting height for yourself and adjusting the legs accordingly.
- I also found that there is plenty of room for a third pan behind the 1/2 pan on the right. A 1/4 pan, turned sideways, has the same width as the half pan and can be used for trash disposal through a hole cut into the top of the cutting board. This frees up your 6"-deep 1/2 pan for ice and drinks, while the full pan can be used for storing food.
- Hooks can be added to the edges of the cart for grilling utensils. I have hooks for tongs, a large spatula, and a mitt.
If you decide to build this cart as cheaply as possible, still expect to dish out about $200 when it's all said and done. Enjoy
