Step 7: Make the Notch Cuts

Mark Powers uses a miter saw to make the notch cuts on the leg pieces of a bar cart
Photo: David Prince
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Using a miter saw, make several kerf cuts between the notch marks on the outside faces of the A legs and the inside faces of the B legs. Stop at the midpoint you marked in step 6. Use a chisel to remove the wood.
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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.