DIY Weber Grill Cart BBQ Station

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Introduction: DIY Weber Grill Cart BBQ Station

About: 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 out my site @ http://darbinorvar.com

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!

1 Person Made This Project!

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29 Discussions

0
Kfry66
Kfry66

Question 2 years ago on Introduction

I need a cut lists please and what kind of wood for outdoor only?

0
AnnC17
AnnC17

Answer 4 months ago

8 @ 32 x 2 x 4 inches - legs, nailed or glued together
5 @ 40 x 2 x 6 inches - table top pieces
5 @ 27 1/2 x 2 x 4 inches - top is screwed to these pieces
2 @ 27 x 2 x 4 inches
5 @ 27 x fence boards - bottom shelf

0
JohnF294
JohnF294

6 months ago

For you spazzizz, your right legs are 33 inches and the left are 31.5
The center hole on Weber Wheels is 3 inches (6 inch total face width)
so you're going to drill a hole 1.5 inches up on center and run 3/8 x 4 Galvanized Hex Bolts with a washer and nut securing the other side. Lay the legs flt and pre drill straight through taking caution not to drill through on an angle. The 2x4's will go on top of the legs at the frame giving your grill height approximately 36 inches. All of the other measurements you can back into, just draw it out first. Oh and she can build a table in my backyard anytime.

0
goran1980zg
goran1980zg

1 year ago

is that BBQ station still "alive" ???
I would like to make one but I am scared that wood atound my Grill would go black and burn.
What is the situation in your case ?
Thanks in advance for an answer

0
JerryM140
JerryM140

Question 1 year ago on Step 2

where is the list of materials needed and a cut list for the wood. Others have asked with no reply

2
chrispak
chrispak

Answer 1 year ago

Hi, here's the list from the YouTube Video:

8 @ 32 x 2 x 4 inches - legs, nailed or glued together
5 @ 40 x 2 x 6 inches - table top pieces
5 @ 27 1/2 x 2 x 4 inches - top is screwed to these pieces
2 @ 27 x 2 x 4 inches
5 @ 27 x fence boards - bottom shelf

0
Whiteheadsal.
Whiteheadsal.

Question 2 years ago on Introduction

What size wood and what all do you need for wood in this project?

0
cameronhirsch
cameronhirsch

2 years ago

What a great way to restore your grill. I bought a similar Weber grill last year, and was looking for some inspiration for a cart. Thank's for the great post!

0
Ryack1
Ryack1

2 years ago

how about putting in the dimensions of the BBQ station like height width etc.

0
olemo
olemo

3 years ago

Hello, very nice job indeed ! Can you tell me the approx. weight of the whole cart ? In fact, I need to build a cart for moving my BBQ along a long climbing path round the house, for sure I will put 4 wheels but if I need to tow it with the car its not a godd idea :-) :-) Thanks again !

0
ChadG31
ChadG31

3 years ago

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

0
SabrinaW29
SabrinaW29

Reply 3 years ago

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

0
SabrinaW29
SabrinaW29

3 years ago

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!! ?

0
FillimenaB
FillimenaB

3 years ago

Great Ibble!! Hopefully will build next weekend!!

0
mach1950
mach1950

3 years ago

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!

0
ToolboxGuy
ToolboxGuy

Reply 3 years ago

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.... :)

0
MathieuC2
MathieuC2

3 years ago

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

0
c.r.h.
c.r.h.

3 years ago

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.

0
bruce.desertrat
bruce.desertrat

Reply 3 years ago

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.

0
whip122
whip122

Reply 3 years ago

Do you have a cut list for the wood