If you’re tired of using a boring Styrofoam cooler at your barbecues, it’s time for an upgrade. This outdoor bar cart made from weather-resistant cedar is a perfect solution for serving drinks at your next backyard gathering. With two wheels for easy mobility, a removable top tray for serving, and the ability to easily disassemble for storage or tailgate parties, this project is ideal for the grilling season. Senior technical editor Mark Powers from This Old House shows you how to create this mobile cart using cedar and outdoor-grade materials, with a moderate skill level required for accurate measurements and leg notching.
To get started, cut the lumber for the cart’s components, assemble the trays, and fit the legs into notches for sturdy construction. With a variety of tools needed, such as a miter saw, jigsaw, and drill, you’ll be able to build this stylish yet functional outdoor bar cart for approximately $160 in cedar materials. By following the detailed instructions and putting in about 10 hours of work, you’ll have a beautiful cart ready to serve up cocktails all summer long in your backyard. Cheers to your new, chic outdoor addition!
Materials and Tools Needed
To build a DIY outdoor bar cart, you will need the following materials and tools:
List of materials for the outdoor bar cart
- Cedar lumber
- Nails
- Screws
- Wood glue
- Red brass insert nuts
- Cotter pins
- Axle caps
- Wheels
Tools required for building the bar cart
- Miter saw
- Jigsaw
- Pneumatic brad nailer
- Wood chisel
- Drill/driver
- Drill bits (1/4-inch, 5/16 inch)
- Combination countersink drill bit
- Spade bit (1-inch)
- Slotted screwdriver
- Hex keys
- Sandpaper (120-grit)
- Flat hand file
Preparation and Cutting
Before assembling the outdoor bar cart, the following steps need to be taken:
Cutting lumber for the trays, handle, and cross pieces
Begin by cutting the cedar lumber for the trays, handle, and cross pieces to the required dimensions.
Trimming corners of the top trays for matching height
To ensure a uniform height, trim the corners of the top trays so that all edges match the height of the thinner long sides.
Assembling the Trays
The trays are a crucial part of the outdoor bar cart and should be assembled carefully:
Centering and attaching handles to the trays
Center the handles on each tray and attach them securely using nails or screws to provide a sturdy grip when moving the cart.
Gluing and nailing components for tray construction
Glue and nail the components together for both the top and bottom trays to create a stable platform for serving drinks and snacks.
Constructing the Legs
The legs provide support and mobility to the outdoor bar cart and require attention during construction:
Preparing longer and shorter legs
Cut the cedar lumber to make longer and shorter legs as per the specified measurements to ensure stability.
Cutting notches and drilling holes for leg assembly
Cut notches in the legs for proper fitting and drill holes for assembly, ensuring that they are aligned correctly for a secure structure.
Adding Cross Pieces and Bottom Tray
Attaching the cross pieces and bottom tray is essential for the structural integrity of the bar cart:
Attaching cross pieces and bottom tray to the legs
Secure the cross pieces and bottom tray to the legs using nails and screws, making sure they are aligned properly for stability.
Drilling holes and securing with connector bolts
Drill holes and secure the legs to the crosspieces and bottom tray using red brass insert nuts and connector bolts for added strength.
Mounting the Wheels
Mobility is key for an outdoor bar cart, and mounting the wheels correctly is crucial:
Securing axle and fitting the second set of legs
Ensure the axle is securely attached and fit the second set of legs over it, aligning all holes and components before bolting everything together.
Bolting everything together and adding wheels
Once everything is aligned, bolt all components together and attach the wheels to the axle, using cotter pins to keep them in place.
Building the Bottle Rack
The bottle rack adds functionality to the outdoor bar cart and should be assembled meticulously:
Cutting and assembling pieces for the bottle rack
Cut the cedar lumber to size and assemble the pieces for the bottle rack, ensuring they are glued and nailed securely for stability.
Attaching the bottle rack to the bottom tray
Secure the bottle rack to the bottom tray using nails or screws to create a designated space for bottles, enhancing the cart’s utility.
Final Assembly
The final assembly involves putting all components together for a functional outdoor bar cart:
Arranging trays and mounting the bottle rack
Arrange the trays and mount the bottle rack securely, ensuring everything is aligned correctly for a polished finish.
Completing the outdoor bar cart with wheels and handle
Finish assembling the outdoor bar cart by attaching the wheels and handle, making sure they are securely fastened for easy maneuverability.
Usage and Maintenance
After completing the construction of your outdoor bar cart, here are some tips for usage and maintenance:
Tips for serving drinks and snacks with the bar cart
- Use the outdoor bar cart to serve beverages and snacks at gatherings or outdoor events.
- Ensure all components are tightened and secure before moving the cart to prevent accidents.
- Clean any spills or stains promptly to maintain the cart’s appearance.
Cleaning and storing the outdoor bar cart
- Regularly clean the cart with a damp cloth to remove dust and dirt.
- Store the outdoor bar cart in a dry and covered area when not in use to prolong its lifespan and prevent damage from the elements.
Conclusion
Building your DIY outdoor bar cart is a rewarding project that enhances your entertaining capabilities. By following the steps outlined above, you can enjoy a stylish and functional cart for serving beverages at gatherings. Remember to store the cart safely to ensure its longevity and usability for future occasions. Enjoy the convenience and versatility of your outdoor bar cart wherever you go!
