Portable Grill and Cooler Cart

 

Between tailgating at sporting events, camping with the family, or maybe even taking advantage of hunting season, it’s time to get out those grills and coolers. What better way to utilize space, and put those two things together?

Steps

  1. Pick out the cheapest single burner portable grill you can find.  Measure the cooler and compare the measurements to the grill to make sure the dimensions can accommodate both.
  2. Make four corner brackets for both the top (grill compartment) and the bottom (cooler compartment).
    Pocket drill
  3. Round over the two edges on one face using a round-over bit and use wood glue and 1-1/4′′ screws to secure the planks to the “L” bracket corners.
    L brackets
  4. For the bottom, secure 4 planks to allow drainage in case any water or ice spilled at the bottom of the cooler compartment. Finish off the cooler compartment with 1-1/2′′ ripped cedar pieces.
    Cedar planks
  5. Build the grill compartment the same exact way as the cooler compartment but then also split it in half on the table saw to create a lid for the compartment.
    Table saw
  6. Make the top using wood glue and pocket hole screws. Secure it to the top of the grill compartment cover using wood glue and 1-1/2′′ brad nails.
    Brad nailer
  7. For the base of the grill compartment, use only two planks on both sides of the base (of the grill compartment) to support the grill.
    Grill compartment base
  8. Use tension lifts to make grill compartment lift up.
    Tension lifts
  9. To ensure the grill compartment slides out, mark underneath where the hardware sits during the “dry fit.” After marking, cut the back out for the slides to go in.
    Dry fit
  10. For the slides, use 1/4′′ aluminum “C-Channel” from the hardware section at your local hardware store. This allows for the grill compartment to lift and then slide out to be able access the cooler easier.
  11. Cut the slides to size and then drill four holes through both sides of each slide. One hole is for the screw and the second is to feed the screw and drill through and secure.
    C-channel aluminum
  12. After drilling, the lift hardware is now able to slide and run through the “C-Channel”.  It should slide out 5 inches and then lift up. The slides are rated to support 100 pounds when extended.
    100-pound supports
  13. For the wheels, use 7′′ plastic lawn mower wheels and secure them using 1/2′′ wide by 4-1/2′′ long partially threaded bolts with 2 washers and a locking nut.
    Wheels
  14. The opposite side of the wheels should have two pegs that would support the stand. Note: you can choose not to have all 4 wheels to allow for easier turning.
    Pegs
  15. For the grill compartment cover, install 2 of the 3-inch hinges to allow for the lid to open and close. To keep the lid from hyper-extending and potentially tipping the cart over, secure the lid using a chain and a “D-Link”.
    Chain
  16. Rough sand everything flush using 80 Grit sandpaper to prepare for the finish. To make this cart weather resistant, use a Shou Sugi Ban wood preserving technique to prevent any rotting or insect infestation.
    Torching
  17. Burn the wood black with gas propane and the Bernzomatic TS8000 Torch with an adjusted flow to control the burning evenly.
    Burning with torch
  18. After the burning was done, seal everything using 5 coats of Boiled Linseed Oil and brush it on using a cheap brush until the oil stopped absorbing into the wood.
    Linseed oil
  19. Install locking hardware and plenty of handles, and if needed, replace the wheel to get this cart ready.
    Installing hardware
  20. After dropping the grill and cooler into its new home, this Portable Grill and Cooler Cart is ready for tailgating, camping or hunting.
    Complete project
    Complete project

What You'll Need


TS8000
TS8000

Max Heat Torch for Faster Work Times

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TX9
TX9

14.1 oz. Propane Hand Torch Cylinder

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Tools

  • Circular Saw
  • Drill
  • Pocket Hole Jig/Saw
  • Brad Nail Gun w/ Air Compressor
  • Oscillating Sander
  • Trim Router
  • Table Saw (Optional)
  • Multi-Oscillating Tool (Optional)

Materials

  • 15 1×4 Cedar Boards
  • Portable Grill
  • Cooler
  • Bernzomatic Propane w/ TS8000 Torch
  • Lift Hardware
  • 1/4′′ Aluminum C-Channel
  • 7′′ Wheels w/ Hardware
  • Wood Glue (Water Resistant)
  • Boiled Linseed Oil w/ Brush
  • 80 Grit Sandpaper
  • 1-1/4′′ Screws
  • 1-1/2′′ Brad Nails
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