Step 6: Cut and Mark the Legs

Mark Powers marks notch locations on the leg pieces of a bar cart
Photo: Kristine Larson
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Refer to the illustration for all dimensions. Use a miter saw to make parallel 45-degree cuts on four 1x2s to cut them to size. Cut ¼ inch off the long points at each end. Lay the A legs on the flat and side by side, with the cut-off long points flush at one end, as shown (the short points meet at the other end). Mark each leg's surface as an "outside face." Measure and mark hole and notch locations on both legs. Repeat for the B legs, but mark each leg's surface as an "inside face."

Turn all the legs on edge. Mark each one at the midpoint of the edge, between the marks, to designate the depth of the notch cuts.

Tip: When marking multiple pieces to be drilled or cut in the same spots, measure off the first one and use a combination square to transfer the marks to other pieces at the same time.
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    Tools List

    • miter saw
      miter saw
    • jigsaw
      jigsaw to cut handles for the top tray
    • pneumatic brad nailer
      pneumatic brad nail gun with 1 3⁄8-inch brad nails
    • chisel
      wood chisel to clean up notch cuts
    • drill
      drill/driver with various bits: ¼ inch, 5⁄16 inch, 3⁄8 inch, combination countersink, and 1-inch paddle
    • flathead screwdriver
      large flathead screwdriver
    • hex keys
      hex key sized to the hex-head connector bolts
    • sandpaper
      120-grit sandpaper and block wood file

    Shopping List

    1. 1x2 cedar for the cart's legs and the ledges for the trays. Buy 22 feet.

    2. 1x3 cedar for the trays and bottle rack. Buy 30 feet.

    3. 1x4 cedar for the tall sides of the top tray and bottle rack. Buy 6 feet.

    4. 2x deck pickets of cedar or treated lumber to make the crosspieces that support the removable top tray.

    5. paint can to trace the shape of the handles for the top tray.6. wood glue

    7. 1-inch hardwood dowel

    8. ½-inch-long brass insert nuts, ¼-20 size

    9. 40-millimeter-long hex-head connector bolts, ¼-20 size

    10. 1½ inch stainless-steel screws

    11. 5⁄8-inch aluminum screw posts

    12. set of two 9-inch wheels with axle, cotter pins, and axle caps.