How To Build a BBQ Cart for a 22" Weber Kettle.

This video illustrates how I built my BBQ cart for my 22 1/2 inch Weber Kettle grill. The frame is simple; using 2x4 standard pine lumber, screws and glue. From the creation of the basic frame, the bottom shelf (floor) was installed using 1x4 x 24" lumber. The top of the cart (the actual work area) was made using 2x6 x 32" standard pine lumber. You'll notice that there is one 2x4 board on the top surface near the grill. My original plan was to use 2x6 lumber lengthwise on the top and not crosswise as demonstrated. My change caused a 2 inch shortage to the top thus, the 2x4 was used to correct the issue. If you do not like this configuration, simply increase the length the cart by 2 inches or shorten it by 3 and 1/2 inches. It is extremely important that from the very beginning, you keep all joints square. This will avoid issues and headaches later in the project.
Also, in the video you'll see I used a "close nipple" for the handle. After I installed it, I realized that the "close nipple" configured the handle much too close to the cart frame causing pain to the knuckles! I switched that out to a 2 1/2 inch nipple. Much better!!!

-A second video will be published, illustrating how I stained the cart and what products were decided upon and used. I anticipate the final video to be released sometime between now and early June 2020. I'm a front line worker with deceased individuals. I have been working long and unpredictable hours. Please be patient. I have a great idea for the table top finish AND I added casters to the front.

I hope this video helped you if you’re attempting a similar project. This was an easy project and a lot of fun to build as well. Feel free to leave questions and/or comments below. I will respond to them as quickly as I can.
-It should be understood that I AM NOT A CARPENTER AND DO NOT CLAIM TO BE ONE. I'm sure there are points in the video that could have been done better or more efficiently by a professional.

I have a Basic Materials List thanks to viewer Chris Flynn who took the time to develop one based on my video. Please leave a comment giving special thanks to him. Here is the basic Material List:

Basic Materials List:
6 ea. 2x4
4 ea. 2x6
3 ea. 1x1
5 ea. 1x2
11 ea. 1x4
4 ea. 3/4” x 3” angle brackets
1 1/4” screws
2” screws
2 1/2” screws
1/2” pipe, 24” long
2 ea. 1/2” pipe nipples
2 ea. 1/2” pipe flanges
2 ea. 1/2” threaded pipe elbows

FRAME:
(2x4’s)
3 @ 24” (top under support)
4 @ 35” (legs)
2 @ 30” (top end-caps)
2 @ 24” (bottom shelf support/end-caps)
2 @ 56” (top rails)
2 @ 53” (bottom shelf support/rails)
1 @ 32” (extra table top piece to make up for an incorrect measurement)

(2x6’s)
10 @ 32” (table top)

CABINET (this ones tricky, so double/triple check my work):
(1x4’s)
20 @ 24” (cabinet sides/back”
6 @ 22 1/2” (shelf)
8 @ ~24 3/4 (doors; two of these to be ripped to 2 1/2”)

(1x1’s)
6 @ 23” (headers, side nailers, side shelf support)
2 @ 21” (back header, back nailer)

TRIM PIECES:
(1x2’s)
2 @ 58 1/2” (top)
4 @ 24” (cabinet horizontal rails)
4 @ 21” (cabinet vertical stiles)
4 @ 13” (door horizontal rails)
4 @ 21 3/4” (door vertical stiles)

(1x1’s)
2 @ 25” (bottom shelf trim, sides)
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Amazon Affiliate Links:
-Blackweb 66" Tripod: : https://amzn.to/2tOZOsD
-Ryobi Biscuit Joiner Kit: https://amzn.to/2XFH10B
-Chicago Electric 10" Table Saw: https://amzn.to/2ISoATe
-Chicago Electric 1/2 in. Heavy Duty Variable Speed Reversible
Hammer Drill: https://amzn.to/2VELQp5
-Cabinet Handles (2): Hickory Hardware® Pipeline Collection: https://amzn.to/2XAPWR4
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Products and Tools Used In This Video:

iPhone 7 Plus - 128 GB
Blackweb 66" Tripod
Craftsman Biscuit Joiner - #17501
Black & Decker 7 1/4" circular saw
Chicago Electric 10", 15 Amp Industrial Bench Table Saw - #97896 (Harbor Freight)
Black & Decker 3/8 drill
Chicago Electric 1/2 in. Heavy Duty Variable Speed Reversible Hammer Drill - #68169
(Harbor Freight)
Craftsman Hand Tools
-Hinges (4): 3 inch - 1/4 inch radius GATE HOUSE brand #0308927. Model S841-539 (Purchased at Lowes)
-Cabinet Handles (2): Hickory Hardware® Pipeline Collection 160mm C/C Black Nickel Vibed
Casual Pull. Model Number: HH075010-BNV (Purchased
at Menards)

I Would Like to Give a Special Thanks to:
-My wife, Shawn - for her support and assistance with the production of this video
-My son, Jacob - for his assistance with the building of the cart, camera operations and grip
-My neighbor, Doug Moore - for his consultation, ideas and his contribution which included the power biscuit joiner and the loaning of some specialized tools (large wood clamps, etc.).
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