How to Build a Grill Cart

It’s grilling season, baby. Last year, you upgraded to a brand-new grill. This year? It’s time to take your setup to the next level with a custom grill cart. We teamed up with Ford to show you how to create one yourself with the 2021 Ford F-150. Utilizing features like the available Tailgate Work Surface to work anywhere and the available Pro Power Onboard to power your tools, you’ll be hosting summer barbecues in no time. See the full instructions below. For even more inspiration, check out our full list of summer projects here.

Step 1: Gather Your Materials

• (7) 2” x 4” x 8’ pine stud
• (3) 2” x 8” x 8’ Douglas fir board
• (4) 3” casters (2 swivel, 2 non-swivel)
• (4) 2"x 2” right angle braces, 3’ long
• 24” x ½” iron bar
• 18” x ½” iron bar
• (4) ¾” reducing Ts
• (4) ¾” flanges
• (4) ½” caps
• (4) ¾” x 2” nipples
• (250) 3” wood screws
• (100) 1” crown-head sheet metal screws
• 1 pt. butchers block oil
• 2 cans spray paint of your choice
• Drill with drill bits and driver heads
• ¼” metal hole drilling pilot pit
• Level
• Measuring tape
• Speed square
• Chop saw
• Orbital sander
• Furniture clamps

Step 1: Make the Following Wood Cuts

• (6) 2” x 4” @ 18”
• (6) 2” x 4” @ 15”
• (6) 2” x 4” @ 27”
• (2) 2” x 4” @ 30”
• (4) 2” x 8” @ 30”
• (3) 2” x 8” @ 42”

Step 2: Assemble Shelf Frames

Screw shelf frames together with glue. Place 30” shelf tops on bottom two shelves. Leave one shelf open on top. Lay out all three pieces on a flat surface with corner brace. Use a cut-off from a 2” x 8” to determine space between top two shelves. The bottom of the bottom shelf should line up with the corner brace. Use this spacing to mark where to make holes in corner brace.

Step 3: Drill Holes in Legs

Drill holes through corner brace. After making holes in one, line up others to make matching holes.

Step 4: Spray Paint Legs

Roughly sand all sides of corner braces so the spray paint adheres. Spray the color of your choice. Remember to spray both inside and outside. Let dry.

Step 5: Assemble and Add Hardware

Sand shelves with orbital sander while braces are drying. After braces are completely dry, line up with shelves and carefully screw in one by one. Make sure all sides are tight to the brace while screwing in. Add top shelf and casters to bottom. Assemble iron pipes into bars to hook accessories onto. Install accessory hangers. Oil surfaces with butcher block oil.