This idea came about whilst i was grilling for a dinner party. I had the tongs in one hand, a hot pad in between my teeth and a glass baking dish holding the marinated chicken just waiting to be cooked. Why was it waiting?? Because I do not have enough table space on my grill to set said baking dish down so I can focus on cooking the dinner. ;)
After much thought i realized i am not the only grill master who has been in this position before. So i opened up some drawing software and began my journey!
Step 1: Concept Drawings
First things first. You need a vision in order to complete this project. My vision looked like the above drawings that i have included. I did not want the top tool rack to be to high so i used a drawing of a person to keep things in scale and perspective.
Once you have your drawings, you can start to gather your tools and materials to start the project. As always Measure once, cut twice.. or is it the other way around?
Step 2: Tools and Materials
I mostly used scrap wood from around my yard. However, I realize not everyone has this option. In the photo, you will notice that the back legs have been bound together by some steel brackets, that is because the wood was pre cut to a different size for another project.
Here is a list of the wood types I used:
Pressure treated 4x4 wood beams. I used approximately 18 feet of it.
60x32 particle wood for table top
4 inch wide x 1/2 inch thick wood slats for the top or tile. What ever you choose
white plastic lattice for front cover
2x6 x 60 for top tool rack and pan holder
Dimensions for my table:
36 inches from ground to table
72 inches from ground to tool rack
60 inches from left to right
32inches front to back
Here are the basic tools i used:
sheet rock or wood screws
most importantly, a pencil
Step 3: Building the Legs
I cut my two front legs of the table to be roughly 36 inches high. The rear legs are at 72 inches from ground level. I chose this height so that my Drum smoker would fit into the covey of the table. I do have to raise my grill up on blocks though in order to use it :)
Once the legs were cut, i began framing the legs with standard 2x4 as shown in the pictures. And yes that is Santa Clause in the photo. He is my dad and i was using his workshop:)
Once you begin to frame, be sure that the frame is level and square or you will have a table that rocks back and forth;)
Once it was framed, i used exterior paint to cover all the wood to protect from weathering. I used about 2 coats of paint and i let set up for 6 hours before i started to work again.
Step 4: Hole Placement
Once the frame was dry, i cut a top for the table out of standard particle board. Depending on your design, hole placement can be put where ever you want. I placed mine closer to the edge so i would have counter space to place food, items, tools, etc etc. I used the lid of my grill to get an idea of the shape i was looking for. I made the "U" shaped hole large enough to allow my drum smoker, grill, and rotisserie to fit.
I used a standard saws-all to cut the hole. Once cut, i tested to make sure the grill and rotis would fit. Notice the grill is on blocks, if not, the rotis unit would not be functional. No big deal for me. I may build a second set of legs for the grill to make it taller.
After making sure the hole was to par, i painted the top with a coat of gripperz paint. KIt is a very thick and sticky paint that can be applied to tile, cement, glass and pretty much anything. It will stick and become water proof. To this day, the top is still in good condition.
Once painted, i allowed to dry for a few hours and began construction on the design to be placed over the painted particle board.
I used wood slats to cover the painted top. I wanted it to look like a "wood floor".
As you can see in the images, i used pine wood slats to cover the painted top. I cut them to the size i wanted and screwed them down to the top.On the right side where my counter space is, the weight of the wood caused the top to bend, An extra leg was added under that portion to ensure stability.
The slats were covered in what i thought was a water proof oil, however after a year, they warped and now the slats need to be replaced. Be sure to cover all the slats with a high quality exterior paint so that rain, snow and sun do not damage the product. Once that is complete, add a decorative lattice to the front and you are ready to go!
I hope you all enjoyed this instruct-able. It was fun to design this table and to share it with others so that they to can have a fantastic summer and grilling season.