Introduction: DIY Weber Grill Cart BBQ Station

This grill cart features a sturdy wooden base with an opening for a round charcoal grill, I used a Weber. The cart also has wheels so you can move it and a rack for pushing / holding tools. If you're looking for a better outdoor cooking experience, then this is perfect as it gives space for chopping, storing etc! Overall this is a great weekend project because it's pretty quick to put together, and if you're organized it can definitely be done in a couple of hours.

Step 1: Cleaning the Grill

The first thing I did was to clean the old grill. I sprayed it with water, scrubbed it with coarse steel wool and really focused on some rusty spots, and then I spray painted all those areas with some heat resistant black paint.

Then I took the grill apart, and removed the wheels - I'm going to be using those for the cart to make it movable.

Step 2: The Wood

Next up, the wood. I cut all the pieces to length on the miter saw, so they were all ready to assemble.

Step 3: Steel Pipes

OK, so I've got some steel pipes and connectors here. This is for a handle for pulling the cart and to work as a towel bar. Here I'm cleaning them up with some denatured alcohol before being spray painting, and I used an oil rubbed bronze color.

Step 4: The Top

Now, let's start putting this thing together! I started with assembling the top together. I put in two supporting pieces first underneath, and then put down the top pieces which I screwed down. Next I'm using a large compass, and I'm making a circle that is just a touch smaller than the grill's diameter. Then when I knew where the grill would come out to, I could mark and attach the last support piece. (watch the video for a clearer demonstration)

Step 5: The Legs

For the legs I'm putting together two 2x4s which I screw together. Two of the legs will be slightly shorter than the others to account for the wheels.

And here are the leg sections. I'm also going to add some support pieces in the middle, and then the wheels on the ends.

Step 6: The Wheels

Now before I left home, I drilled some very small holes in a steel rod, and the wheels will slide on the rod, and these cotter pins will make sure they stay in place. Then I drilled a hole in the two shorter legs for the rod to come through, and then I secured it with the pins.

Step 7: Cutting the Hole

OK, so time to cut out the hole for the grill with my jig saw.

I began with drilling a started hole, and then I followed along the marked circle with the jig saw.

Initially I had planned on putting in several screws in the wood to prevent direct contact with the wood. But after looking at it, I realized that the grill only touched a couple of areas, because the circle was not perfectly even, so I decided to skip that. There is no danger with this and if any scorching actually did occur it will be easy to add the small screws to decrease the contact.

Step 8: Bottom Shelf

I also decided to add some cap pieces on the ends to the cart to finish it off a bit.

On the underside I'm adding some cedar fence boards for a shelf, and this is where I picture you would store extra charcoal and things like that.

Step 9: Sanding

Next up - sanding, mostly on the top to make it nice and smooth.

Step 10: Finishing Touches

Now remember the cart handle I painted, well here I have it assembled and just screwing this bar in on the side of the cart. And you can hold on to this when moving the cart, or use it to hang tools or whatever. Lastly I put on a thick coat of spar polyurethane on the whole cart to protect it from the elements.

Step 11: Conclusion - Watch the Video

To get a look at the final result, and a much better idea of the process of the build, make sure to check out the video!

Comments

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ChadG31 made it!(author)2017-07-11

It would have been nice to have a cut list for the wood!

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SabrinaW29 made it!(author)2017-07-11

Yes , it would be nice to have a list of the cuts that were made.Can we get a list please? Thank you :-)

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SabrinaW29 made it!(author)2017-07-11

This project is a wonderful idea!! I'm going try it. The one thing that I'd like to do is ,to make the table longer. I guess that I could make the table to the video's measurements ,and build a stationary table , and have the BBQ station attach together with the other when I want to BBQ? Any ideas or help with my idea anyone? Have a great day!! ?

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FillimenaB made it!(author)2017-07-11

Great Ibble!! Hopefully will build next weekend!!

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mach1950 made it!(author)2017-07-04

Great instructable thank you. I wonder if you've used it yet and if you found any scorching? I like your idea of inserting screws to hold the bowl off the wood. Simple but effective!

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ToolboxGuy made it!(author)2017-07-11

Good idea with the screws - you could easily add a few washers to work as spacers, to give an extra air gap - right where your jig saw cut went outside the lines.... :)

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MathieuC2 made it!(author)2017-07-11

Very good work ! You have the dimension to do mine?

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c.r.h. made it!(author)2017-07-11

Nice Idea but any safety concerns? Wood in direct contact with the Weber. Maybe create an air gap between the grill and the table top and suspend the grill in a fire safe way.

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bruce.desertrat made it!(author)2017-07-11

The outside of the Weber should never get hot enough to burn the wood. I made a metal version of this to fit mine using bed rail, an have it set in the opening with pieces of high-temp auto vaccum tubing as a bumper. It's fine after several years of grilling.

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whip122 made it!(author)2017-07-11

Do you have a cut list for the wood

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pbrichta138 made it!(author)2017-07-11

Wood doesn't even begin to char or release flammable gas until nearly 600 degrees Fahrenheit, and won't actually catch fire until over 1000 degrees. So as long as you're only grilling in there and not using using it as a makeshift bonfire it will be just fine. Bbq past 400 degrees will be inedible.

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whip122 made it!(author)2017-07-11

Do you have a cut list for the wood used?

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leepettijohn made it!(author)2017-07-11

Cool idea. Thanks

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MikeS1024 made it!(author)2017-07-11

Nice job - "DIY Weber Performer." Consider adding the propane ignition system to conveniently light the charcoal in addition to the ash catcher?

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ShadowPap made it!(author)2017-07-03

Thanks! It is a great idea and will be doing it when I return from business. Congratulations on your future new arrival (Project)!

As a Grandfather of 7, I know you will be very busy!

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Nuonaton made it!(author)2017-06-29

Nice! Now you can add a rotisserie motor to smaller round grills!

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DaveW213 made it!(author)2017-06-29

Nice job! You might look into a Weber Ash Catcher, part #65143

One thing to note about something I saw on the video, which is that painting the inside of a grill isn't recommended. Even a high temp paint will give off fumes. Clean up as much as possible and then give it a thin coat of cooking oil. Then heat it up to set it in. Kind of like seasoning a cast iron pan.

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tytower made it!(author)2017-06-29

Sure looks good ! Now just add a good vice to the side and make it really useful. Hold the sasauges while you skewer them perhaps

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hispanickausinpanik made it!(author)2017-06-29

Very nice ! Great job !

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Bio: Hi I'm Linn and on my Youtube Channel I have lots of great videos about building, construction and fun projects. You can also check ... More »
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