Step 13: Assemble the Cart Bottom

Mark Powers attaches the crosspieces to the bottom tray of the bar cart
Photo: David Prince
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Stand the bottom tray on a long side and the crosspieces on their ends. Lay one set of the cart's legs over these pieces, handle recess facing down. Line up the pilot holes with the insert nuts in the tray and crosspieces. Using a hex key, twist hex-head connector bolts through the holes and into the nuts. Fit one end of the handle into the recess, and use a 1½-inch stainless-steel screw to secure it to the leg through the countersink.
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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.