Brad from Fix This Build That shares a fantastic project for creating a Patio Cooler and Grill Cart combo that’s perfect for outdoor gatherings. This guide will provide you with all the steps and materials you need to create this handy addition to your backyard.
Materials and Tools Needed
- 1×4 lumber for the frame and legs
- 2×4 lumber for the cooler support
- Wood glue
- 1 1/4 inch pocket hole screws
- Brad nails
- Cleats for structural support
- Half-inch PVC for the drain
- Utility hinges
- Handle for the lid
- Bottle opener
- Spar urethane for finishing
Step 1: Build the Top Frame
Start by constructing the top frame using two long pieces for the length and three shorter pieces for the width of the cooler. Drill pocket holes in the underside of the short pieces to attach the frame together. Position the middle piece, secure one side, put the cooler in place, and draw a reference mark on the boards. Then screw the rest of the frame together with pocket screws.
Step 2: Cut the Legs
Next, cut the boards for the legs. Each leg should be 38 1/4 inches long, giving a total height of 39 inches when the top is added. Each leg is made from one full-size 1×4 and one ripped down to 2 3/4 inches. Assemble the legs using pocket holes, glue, and clamps.
Step 3: Prepare the Sides
Cut the boards for the front, back, and sides of the cart. The front and back will each need four long boards at 44 1/2 inches, while the sides will be cut at 16 1/2 inches long, also needing four boards per side. To add detail, use a chamfer bit in a trim router to create a 1/16 inch 45° chamfer on the edges of all cladding boards.
Step 4: Assemble the Sides
After the glue on the legs has dried, lay out the pieces to assemble the sides. Apply glue to the legs and tack the side cladding in place with a brad nailer. Pre-drill and screw the pieces together with 1 1/4 inch screws.
Step 5: Attach Front and Back
Join the sides with the front and back cladding using the same method of glue, tack with brad nails, pre-drill, and secure with screws. Prepare for attaching the top later by using a combination of pocket holes and cleats.
Step 6: Construct the Storage Bay
Cut four boards to 15 inches long for the storage cavity wall and attach them to the cleats with screws and glue. For the bottom of the storage bay, use cleats installed 3/4 inches up from the bottom to maximize capacity.
Step 7: Attach the Top
With the storage bay complete, line and attach the top using cleats and screws. Apply glue along the top edge for added support.
Step 8: Create the Lower Shelf
For the lower shelf, use two 46-inch long strips and 1-inch wide boards. Start by securing the outer boards and then fill in the middle using a spacer to ensure even gaps.
Step 9: Install the Cooler
Install the cooler into place. The handles of the cooler should fit snugly against the top. Turn the cart upside down and secure three 15-inch boards against the cooler’s bottom.
Step 10: Make the Lids
Construct the lid for the storage area, ensuring it sits flush with no handle or hinges. Create a finger hold by drilling a 1-inch hole in the first board and chamfer the edges for a smooth finish.
Step 11: Final Assembly
Assemble all parts and ensure a clean look for the top. Build a frame around the lid and attach the boards securely. Install the drain hardware using half-inch PVC and male adapters.
Step 12: Finishing Touches
Apply a thick coat of Spar urethane to finish the wood. After drying, attach the hardware, including utility hinges, a handle, and a bottle opener.
Enjoy Your New Grill Cart!
With everything assembled, this Patio Cooler and Grill Cart combo is ready for use. Perfect for your outdoor gatherings, it combines functionality with style. Enjoy your grilling and chilling! Get the plans here.
