Introduction: Reclaimed Barn Wood Bar Cart

Picture of Reclaimed Barn Wood Bar Cart

This was a project I made for my parents for Christmas. All of the materials were found in an old horse barn on my brother's property. By the look of the old, square hand made nails this wood must be over 100 years old. The only thing "new" on this cart is the handle which is actually an upside down towel rack.

I will provide the measurements but they can be easily changed if you want.

I used reclaimed barn wood but any wood can be used.

Step 1: Cut Support and Tray Frame Pieces.

Picture of Cut Support and Tray Frame Pieces.

Uprights - Qty. 4 - 33.25" x 2.75" x 1.25"

Bottom shelf supports - Qty. 2 - 24" x 2.75" x 1.25"

Middle shelf supports - Qty. 2 - 13.5" x 2.75" x 1.25"

Tray Frame (cut all ends at 45 deg.) - Qty. 2 - 32" x 2.75" x .75"

Qty. 2 - 22" x 2.75" x .75"

Step 2: Assemble Frame

Picture of Assemble Frame

Attach shelf supports to uprights using pocket screws.

Step 3: Top Tray Frame

Picture of Top Tray Frame

Using a router, cut a 3/4" square grove on the inside of all 4 tray frame pieces. 1/2" inch from the bottom. 1/4" deep.

Step 4: Top Tray Assembly

Picture of Top Tray Assembly

Tray Base boards......... Qty. 3 - 31" x 5" x .75" Qty. 2 - 31" x 3" x .75"

Assemble frame pieces around base boards and secure with brad nails and glue.

Center the Top Tray onto the cart frame and attach with pocket screws.

Step 5: Bottom and Middle Shelves

Picture of Bottom and Middle Shelves

Middle shelf....... Cut boards and assemble together to make a 26" x 13.5" shelf and attach to middle shelf supports with screws or brad nails.

Bottom shelf........ Cut boards and assemble together to make a 26" x 16" shelf. Using a jigsaw cut out pockets in all four corners for the support legs. Attach to bottom shelf supports with screws or brad nails.

Step 6: Finish

Picture of Finish

Install wheels (I used 8" wheels), front support pegs (length will be determined by the size of your wheels), handle and other accessories. I added a bottle opener and wine glass hangers.

Step 7: Enjoy.

Picture of Enjoy.

This is a fun and rather easy project for the weekend woodworker like me. I have a small woodshop with inexpensive tools. That's all I needed for this project.


KyleD14 (author)2016-01-22

Curious where you found the bottle opener to mount on the side. I've not seen one in that finish.

djdannyvan (author)KyleD142016-01-25

Mine came from Bed Bath & Beyond. I found this one on Amazon for around $4.

BeachsideHank (author)2016-01-22

One can simulate the look of a cut nail:

by hammer folding the head of a typical "penny" nail into a "T" shape. Great for a faux antique looking project.

DIY Hacks and How Tos (author)2016-01-22

Great looking cart. I love the look and feel of reclaimed weathered wood.

Thank you!

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