Step 16: Build the Bottle Rack

Mark Powers assembling the bottle rack for the bar cart
Photo: Kristine Larson
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Refer to the illustration for dimensions. Cut two 1x4 long sides, two 1x3 short sides, and three 1x3 bottle spacers. Follow the process in step 4 to glue, butt, and nail the joints together. Start by attaching the edge of a long side to the end of a short side so that they're flush at their top edges. Next, attach the edges of the spacers along the inside face of the long side, flush with its bottom edge and spaced at proper intervals (use bottles to size them). Attach the second long side to the end of the first short side and the edges of the spacers; it should be flush with the top of the short side and the bottoms of the spacers. Finish by attaching the edges of both long sides to the ends of the second short side, flush at their tops. Fit the rack onto either tray to hold bottles in place.

Tip: If you leave the cart unfinished, the cedar will weather to an attractive silvery gray—just like a beach house. If you'd rather preserve the color of the wood or bring out its red undertones, apply a clear toner, such as Penofin, annually.
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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.