DIY Weber Grill Cart BBQ Station

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.

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.

Next up, the wood. I cut all the pieces to length on the miter saw, so they were all ready to assemble.

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.

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)

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.

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.

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.

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.

Next up - sanding, mostly on the top to make it nice and smooth.

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.

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!