The Home Depot how to build a rolling bar cart

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The Home Depot is the world’s largest home improvement specialty retailer.

Created By BlankSlate

Is your kitchen short on counter space or do you entertain often in your home? A solid rolling bar cart is an excellent way to gain extra space and serve your guests. It features two shelves, one to hold barware and the second to hold bottles. Smoothly rolling casters and functional storage hooks from The Home Depot make this a stylish and functional entertaining cart.

Through this step-by-step tutorial, let’s build a cart that you can use for entertaining indoors and outdoors.

All photos by Weatherby Photography.

What you need for this job:

TOOLS:
● Measuring tape
● Rafter square
● Miter saw
● Kreg Pocket-Hole Jig
● Drill
● Bar clamp
● 90-degree corner clamp
● Wood glue
● 18-gauge brad nailer
● Circular saw
● Table saw
● Jigsaw or Hand saw
● Random Orbit Sander, for optional finish
● 100- and 200-grit sandpaper, for optional finish
● Dust cloth or tack cloth, for optional finish
● Clean cloths, for optional finish

MATERIALS (prices may vary by region):
● (4) 8′ lengths of 2′ x 4′ lumber, $2.77 each
● (1) 8′ length of 2′ x 2′ lumber, $8.72
● (2) 8′ lengths of 1′ x 4′ lumber, $9.38 each
● 2.5″ Kreg Pocket-Hole Screws, $4.97
● 1.25″ Kreg Pocket-Hole Screws, $4.97
● 1.25″ brad nails, $4.72
● (2) 20″ x 48″ laminated pine panels, $15.34 each
● (4) Everbilt Industrial Duty Swivel Casters, $5.48 each
● 12 small washers, $0.50 each
● White spray paint, for optional finish, $0.97
● Minwax Dark Walnut Stain, for optional finish, $7.77
● Minwax Satin Spray Lacquer, for optional finish, $8.98
● Cabinet pulls, Liberty hooks ($3.28 each), wine glass holders ($5.27), and drawer knobs, for optional finish and final decoration

 

Let’s get started>

The Home Depot how to build a rolling bar cart

Step 1 – Make Your Cuts
Mark your cuts using a measuring tape and rafter square. Use a miter saw to cut the 2′ x 4′, 2′ x 2′ and 1′ x 4′ pieces to the lengths indicated in the lumber cut list:

  • (4) 31″ 2′ x 4′ legs
  • (4) 29″ 2′ x 4′ aprons and bottom supports
  • (4) 13.5″ 2′ x 4′ apron and bottom supports
  • (2) 29″ 2′ x 2′ shelf supports
  • (2) 13.5″ 2′ x 2′ shelf supports
  • (6) 16.5″ 1′ x 4′ shelf slats
  • (2) 13.5″ 1′ x 4′ shelf slats
  • (2) 18″ x 16.5″ laminated pine shelves (notched to accommodate 2′ x 4′ legs)
  • (1) 18.5″ x 38″ laminated pine top

 

The Home Depot how to build a rolling bar cart

Step 2 – Drill Pocket Holes in 2′ x 4′ and 2′ x 2′ Boards
Measure the thickness of the wood and set the Kreg Pocket-Hole Jig to a 1.5″ material thickness and a 2.5″ screw. Drill two pocket holes into each end of all four of the 29″ 2′ x 4′ boards and all four of the 13.5″ 2′ x 4′ boards. Using the same jig setting, drill one pocket hole into each end of each 2′ x 2′ shelf support.

 

The Home Depot how to build a rolling bar cart

Step 3 – Drill Pocket Holes in 31″ Legs
For the main 31″ legs, set the Kreg jig to a 0.75″ material thickness and a 1.25″ screw. Use a screw that’s slightly shorter than the board thickness to prevent the screws from protruding through the bar top.

 

The Home Depot how to build a rolling bar cart

Step 4 – Preset Screws
With the drill, preset each screw into the legs.

 

The Home Depot how to build a rolling bar cart

Step 5 – Assemble the 2′ x 4′ Frame
If you are building this bar cart alone, use a clamp to hold each joint firmly in place as you insert the screws. Or, have an assistant hold the pieces in place. Use the rafter square to check that your assembly is square. With the prepared pocket screws, attach one 31″ 2′ x 4′ (leg) to each side of the top 29″ 2′ x 4′ (apron). Then attach another 29″ 2′ x 4′ (bottom shelf support) to the bottom of each 31″ leg.

 

The Home Depot how to build a rolling bar cart

Step 6 – Add the Center Shelf Support
Mark the location for the bar cart’s center shelf support. The shelf in this tutorial is placed 14.75″ from the bottom, but you can choose a placement that best fits your needs.

 

The Home Depot how to build a rolling bar cart

Step 7 – Assemble the Frame for the Opposite Side
Repeat steps 5 and 6 to make the frame for the opposite side of the cart. When you complete this step, you will have constructed both the front and back frames.

 

The Home Depot how to build a rolling bar cart

Step 8 – Make the Side Aprons and Bottom Supports
Use a corner clamp or an assistant to hold the boards in place. Attach one 13.5″ 2′ x 4′ board to each side of the apron and bottom support of one of the frames.

 

Connecting the frames, shelves, and casters>

The Home Depot how to build a rolling bar cart

Step 9 – Connect the Front and Back Frames
Turn over the cart and attach the back frame.

 

The Home Depot how to build a rolling bar cart

Step 10 – Add Shelf Supports
Insert all four of the 2′ x 2′ shelf supports at the height of the middle shelf and secure with the prepared screws.

 

The Home Depot how to build a rolling bar cart

Step 11 – Attach the First Bottom Shelf Slat
Run a small bead of glue along one of the 13.5″ bottom supports and spread the glue evenly over the length of the bottom support. Place one of the 13.5″ 1′ x 4′ boards on top of the bottom support and align the edge of the 1′ x 4′ board flush with the face of the bottom support. Secure the board with 1.25″ brad nails.

 

The Home Depot how to build a rolling bar cart

Step 12 – Attach the Other Slats to Make the Slatted Shelf
Cut a small 1″ spacer block from a scrap of wood; this spacer block will ensure even spacing between the slats. Spread a small bead of glue onto the ends of each slat and attach 3 of the 16.5″ slats 1″ apart. Secure them each with 1.25″ brad nails.

 

The Home Depot how to build a rolling bar cart

Step 13 – Assemble the Center Slatted Shelf
Repeat steps 11 and 12 to assemble the center shelf.

 

The Home Depot how to build a rolling bar cart

Step 14 – Cut the Solid Shelves
You can use either a circular saw or a table saw for this step. In this tutorial, we used a Ryobi 18v circular saw to make the cross cuts and a table saw to make the rip cuts. Using the rafter square, mark lines for two 18″ x 16.5″ rectangles on a laminated pine panel. Use clamps where appropriate and cut the straight lines.

 

The Home Depot how to build a rolling bar cart

Step 15 – Cut the Notches
Mark 1.5″ x 3.5″ notches in both corners of a 16.5″ side to accommodate the 2′ x 4′ legs. Repeat marking for each shelf. Cut out notches using a jigsaw or hand saw.

 

The Home Depot how to build a rolling bar cart

Step 16 – Attach the Shelves
Attach both shelves using glue and brad nails.

 

The Home Depot how to build a rolling bar cart

Step 17 – Make the Top Surface of the Cart
Use the rafter square to mark lines and cut the remaining laminated pine panel to make an 18.5″ x 38″ top with the circular saw or table saw. Run a bead of glue around the top edge of the frame. Position the frame onto the bottom of the top of the laminated pine bar top.

 

The Home Depot how to build a rolling bar cart

Step 18 – Secure the Top to the Frame
Once you have centered the frame on the top, secure the bar top to the frame using the 1.25″ pocket screws you previously drilled.

 

The Home Depot how to build a rolling bar cart

Step 19 – Attach the Casters
In each corner, attach an Everbilt caster. For each of the casters used in this tutorial, we used three 2.5″ Kreg screws and some small washers to attach the casters to the frame.

 

The Home Depot how to build a rolling bar cart

Step 20 – Turn the Cart Right-Side Up and Move the Cart to Its Desired Location
Great work! Enjoy your completed rolling bar cart.

 

For the optional finish>

The Home Depot how to build a rolling bar cart
Step 1 – Sand the Cart
Use a Random Orbit Sander to sand the surface of the cart. Start with a 100-grit sandpaper and finish with a 220-grit sandpaper to achieve a smooth finish. After sanding, remove sanding dust from surfaces with the tack cloth.

 

The Home Depot how to build a rolling bar cart

Step 2 – Choose Your Desired Finish for the Cart
Finish your cart with stain or paint in a style that will complement the decorating scheme in your house, whether it’s bold and sleek, natural and understated, or warm and inviting. In this tutorial, we finished the cart using a process to make new wood look old. If you want to achieve this appearance, follow steps 3-6 below. If you choose a different finishing method, skip to step 8.

 

The Home Depot how to build a rolling bar cart

Step 3 – Paint the Cart
Apply a layer of glossy white spray paint to the cart.

 

The Home Depot how to build a rolling bar cart

Step 4 – Sand the Painted Cart
Once the paint is dry, lightly sand the surfaces of the cart with 100-grit sandpaper or your random-orbit sander. Remember, the bare wood will show through the paint after sanding and will have a brown appearance. While the white paint will appear grayer in color, you want some grain to show through the paint.

 

The Home Depot how to build a rolling bar cart

Step 5 – Apply Stain to the Cart
Dust the cart thoroughly and apply a generous coat of Minwax Dark Walnut Stain with a clean cloth. Make sure to apply the stain in each crevice and over each area of the cart. Remove any excess stain with another clean cloth. Don’t worry about getting the stain perfectly even. You’re aiming for a rough, rustic appearance.

 

Step 6 – Apply a Clear Coat of Lacquer Over the Stain
Apply three coats of Minwax Satin Spray Lacquer. Lightly buff the surface with a clean cloth between each coat. For a piece the size of this cart, you may need 2 cans of lacquer. Alternatively, use polyurethane to get a harder film finish.

 

The Home Depot how to build a rolling bar cart

Step 7 – Add Hardware to the Cart
Now that your cart is beautifully finished, you can add any functional hardware touches that you like, such as a wide cabinet pull on each side, swinging cabinet doors, or a few hooks to hold bar towels.

 

For more tips on DIY projects and information on tools, visit The Home Depot.

 

 


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