How to build a bar cart

This step by step diy woodworking project is about how to build a bar cart. If you want to learn more about building a bar cart, we recommend you to pay attention to the instructions described in the article. There are so many wooden cart plans and designs to choose from, so make sure you take a close look over the rest of the related woodworking projects that are featured on our website.

Before starting the actual construction project, we recommend you to plan everything, as to save money and to keep the costs under control. Adjust the size and the design of the kitchen cart to suit your needs. In addition, we recommend you to invest in high-quality materials, such as pine, redwood or cedar, as they have a nice finish and are highly durable, especially in a humid environment.

If you don’t have a rich expertise in woodworking field, you should ask a friend to give you a hand with the project. There are many things that you could go wrong, so make sure you plan everything and invest in quality materials. Select the lumber with attention, making sure the components are perfectly straight and in a very good condition. Use a carpentry square to check if the corners are right-angled. See all my Premium Plans in the Shop.

Made from this plan

Building a bar cart

Materials

A – 2 pieces of 2×2 lumber – 34″ long, 2 pieces – 27 1/2″ long LEGS
B – 4 pieces of 2×2 lumber – 35″ long, 4 pieces – 21″ long SUPPORTS
C – 2 pieces of 3/4″ plywood – 21″x35″ long SHELVES
D – 6 pieces of 1×1 lumber – 35″ long, 6 pieces – 21″ long RAILS
E – 1 piece of 2×2 lumber (round) – 21″ long HANDLE
F – 4 caster wheels CASTER WHEELS

4 pieces of 2×2 lumber – 10 ft
1 piece of 3/4″ plywood – 4’x4′
3 pieces of 1×1 lumber – 12 ft
dowel
4 caster wheels
2 1/2″ screws
1 1/4″ screws
glue, stain
wood filler

Tools

Safety gloves, glasses, Miter saw, jigsaw
Chalk line, tape measure, spirit level, carpentry pencil
Drill machinery and drill bits

Tips

Apply several coats of wood stain to the wooden components
Fill the holes with wood filler and smooth the surface

Time

One Day

Building a bar cart

Building the side

The fist step of the woodworking project is to build the back side of the bar cart. As you can easily notice in the project, you need to cut the components out of 2×2 lumber. Drill pocket holes at both ends of the horizontal components and secure them to vertical legs, after making sure the corners are right-angled. Add glue to the joints and leave no gaps between the components.

Building the opposite side

Continue the project by assembling the face wall of the bar cart. In order to get a professional result, we recommend you to mark the cut lines on the components and to get the job done in a professional manner. Leave no gaps between the components and add glue to the joints.

Building the frame of the cart

Continue the bar cart project by locking the back and the front faces of the structure together. In order to get the job done in a professional manner, we recommend you to drill pocket holes at both ends of the horizontal components and to secure them to the walls using 2 1/2″ galvanized screws.

Fitting the shelves

Cut the shelves out of 3/4″ plywood after taking accurate measurements. It is essential to smooth the edges before fitting the piece of plywood inside the frame. In addition, drill pocket holes along the edges of the plywood piece and secure it to the frame by using 1 1/4″ screws. Work with attention and add glue to the joints. Remove the excess with a damp cloth.

Fitting the guard rails

In order to add character to the bar cart, we strongly recommend you to build the guard rails out of 1×1 lumber. Drill pocket holes at both ends of the components and secure them to the legs, as described in the diagram. Place them equally spaced and leave no gaps between the rails.

Fitting the caster wheels

One of the last steps of the project is to attach the caster wheels to the four legs of the bar cart, as described in the image. Select the right caster wheels for your needs and secure them to the legs using screws, after making sure they are aligned properly.

Fitting the handle

In order to get a professional result, we recommend you to build the handle out of round 2×2 lumber. Drill pilot holes the supports and insert 2 1/2″ screws into the handle, as described in the diagram. Add glue to reinforce the bond of the components.

How to build a bar cart

Last but not least, you need to take care of the final touches. Therefore, you need fill all the holes with a good filler and let the compound to dry out properly, before sanding the wooden surface with 120-grit sandpaper.

Thank you for reading our article about how to build a bar cart and we recommend you to check out the rest of our home improvement projects. Don’t forget to LIKE and SHARE this projects to your friends, using the social media widgets, if you’ve found it useful.

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