How to build a DIY grill cart

Note: This post is brought to you by The Home Depot.

Remember my super awesome 6 box vertical planter that I built for a Home Depot workshop back in April? Well, it’s DIY workshop time again, y’all! On Saturday, June 20th at big orange box’s across the country you can attend a free workshop and learn how to build this DIY grill cart just in time for Father’s Day. Better yet, make it a Dad date and learn how to build the rolling grill cart together. I’ll be hosting the workshop in Jacksonville Beach, FL. 

In preparation for this workshop, I built a similar version of the rolling grill for our backyard. We already have an outdoor table very near the grill so work space is not an issue, but the one thing we really needed was a place for a the grilling beverages to stay chilly all summer long! We needed a place to serve drinks that was cuter than a blue cooler and more functional than those galvanized beverage tubs. Shade helps too. It was a high of 93 degrees this week, yikes.

How to build a DIY grill cart

Here are the plans for the DIY grill cart that I will be teaching at the DIY Workshop. I’m sharing this because my version is very similar, minus the middle shelf. Instead of adding the (2) 2×8 and (1) 2×4 as a second shelf, I used that as a frame to attach my wood floor pieces too and cover the sides of the cooler!

Step 1- Cut the wood pieces

These are the wood pieces you will need to build my version of the DIY grill cart.

• Six 19 inch 2×4
• Six 2 foot x 3 inch 2×4
• Two 16 inch 2×4
• Two 2 foot x 6 inch 2×8
• One 2 foot x six inch 2×4
• Three 3 foot x six inch 2×8
• Four casters (Fancy word for wheels!)
• Four 3 food long 2×2 angle irons

Step 2- Build

We started by building the bottom shelf frame. Use a metal square to ensure that all of your angles are square when screwing them together.

Step 3- Attach casters

Here is the bottom shelf frame built and ready for casters! Unless you plan out where you screw your wood frame together, screwing the casters in can be a little tricky. It’s not a huge deal, but we were not able to screw the wheels in at all 4 points.

Step 4- Build shelf frames

Next, we built the other two shelf frames. These are pretty straight forward and simple to build since it is the same as the bottom one without the two shorter pieces inside of the frame.

Step 5- Attach the metal sides

Now, it’s time to attach the metal sides to the shelves. Here are a few tips for drilling screws into the metal posts.

1. For the love, use an impact driver.
2. You need a metal drill bit.
3. Make sure you have the exact right size drill bit. We are using a 9/32 drill bit with quarter inch stainless steel lag screws. Our drill bit is just 1/32 bigger than the screws.
4. Alignment of the screws: Don’t let the lag screws cross each other. One needs to go high and one needs to go low.
5. Alignment of the screws: Watch out for your wood screws that were used to secure your shelf. You don’t want the screws hitting each other.

Step 6- Enclose the cooler shelf

Once the metal sides are attached the three wood shelf frames, it is time to enclose the cooler shelf. We up-cycled wood floors for this part! We cut long wood floor pieces into 19 inch segments, and sanded the heck out of them. Then, we attached them with a nail gun to the lower and middle shelf frame.

Step 7- Add the top

Now, it is time to add the top of your grill cart. The trick here is to screw the boards in from underneath so that your table top is screw hole free. This requires 4 and a half inch long screws so that the screw can go through the 2×4 frame and into the table top.

Step 8- Add hooks

Oh and last but not least, we added hooks for grill necessities like scrubbers and flippers!

Don’t forget to register to attend this DIY Workshop and learn how to build a vertical planter. Jacksonville Beach, FL, I’m coming for ya!

Where: 3790 Third Street South, Jacksonville Beach, FL32250

When: Saturday, June 20th

Time: 10:00am – 11:30am

Cost: FREE!

High five to building things and meeting YOU in person!

Do you need a grill cart in your life?