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Today I’m sharing an awesome project to kickoff your summer outdoor entertaining. This Patio Cooler and Grill Cart combo will be home base for your outdoor BBQs. It's made entirely from cedar 1x4's and sports a 48qt cooler and storage for all your grill accessories. You'll love this in your backyard!
- Miter saw
- Cordless Drill
- Brad Nailer
- Drill bits
- (12) cedar 1x4x12'
- 48qt cooler
- hose bib
- PVC fittings
- 3" utility hinges
- Bottle Opener
Read the instructable here and you can also get a download of the plans with measured drawings over at my website: http://fixthisbuildthat.com/diy-patio-cooler-grill-cart-combo-plans/
Step 1: Build Top Frame
The top of my cooler was 23-3/4″ x 13-1/2″. Size to your coolers dimensions.
Assemble the top frame from 2 50" long 1x4's and 3 13-1/2" 1x4's. Opening on left should fit your cooler. Assemble with pocket hole screws
Step 2: Build Legs
Cut 4 1x4's to 38-1/4" long and 4 more to 38-1/4" long but 2-3/4" wide. Join legs with pocket holes on top 13" and bottom 2" where the screws will be covered. Use clamps in the middle to let glue dry.
Step 3: Assemble Sides
Cut 8 sides to 16-1/2" and glue and screw 4 boards together between a pair of legs. Repeat for the other side.
Step 4: Attach Front and Back
Cut 8 boards to 44-1/2" long and connect the side assemblies by joining the pieces to the legs as you did on the sides.
Step 5: Build Storage Bay
Attach 14" long cleats to the inside of the cart on front and back. Cleat should be 18" from right side.
Cut 4 dividers to 15" long and screw into cleats.
Cut 5 15" pieces and 2 17-1/4" cleats and mount them to the bottom of the storage bay to form the bottom.
Step 6: Attach Top Frame to Cart
Using cleats in the storage bay and pocket holes in the cooler bay, attach the top to the cart.
Step 7: Build Storage Bay Lid
Cut 4 pieces of 1x4 to 15-3/4" to form the top. Drill a 1" hole in the middle of an outer board.
Attach all 4 boards together with 2 battens across the bottom.
Cut 4 2"x1-1/2" corner tabs and glue and nail into the corners of the storage bay to hold the top
Step 8: Mount Cooler
Flip cart upside down and place cooler in cooler bay opening, flush with the top.
Cut 3 15" 1x4's and hold them down on the top and secure to the sides with pocket holes.
Step 9: Connect Drain
Use a 1/2" hose bib and 1/2" PVC fittings to replace the drain on the cooler.
Drill a 1-1/4" hole across from the drain and fit the hose bib and fittings to the cooler.
Step 10: Build Cooler Lid
Build a frame around the cooler with 2" wide boards 25-1/4" long for the front/back and 13-1/2" long for the sides.
Attach 3 13-1/2" cleats to the front and back, resting on top of the lid.
Cut 5 25-1/4" boards for the top, 4 full size 1x4's and the middle board cut to fit. Glue the boards down to the cleats with super glue except the middle board. Flip over the assembly and screw the top pieces down to the cleats.
Replace the top and the cooler lid and secure the cooler to the wood top with screws. Put the final center piece in place with super glue and wood glue.
Step 11: Build the Lower Shelf
Cut 2 1" wide 46" long shelf stretchers and 11 16-1/2" slats. Glue and nail the slats to the stretcher evenly spaced.
Step 12: Apply Finish
Apply an exterior grade finish to all parts.
Step 13: Attach Lower Shelf
Attach lower shelf to the legs with screws so bottom is 2-1/2" off the ground.
Step 14: Attach Hardware
Attach 3" utility hinges to the back of the top, a handle on the front, and a bottle opener on the leg.
Load up the cooler with drink and invite your friends over!
Thanks for reading! If you want a download of the plans with measured drawings go to my website: http://fixthisbuildthat.com/diy-patio-cooler-grill-cart-combo-plans/