When you need extra counter space or a roll-where-you-need-it servery or bar cart, this kitchen cart is the perfect solution. It can be as sleek or as casual as you like, depending on your colour choices and finishes.
- Construct legs
- Cut base and top
- Cut upper and lower surround pieces
- Complete surrounds
- Shape, cut and drill
For each pair of legs, laminate three 8' pieces of 1 x 3 clear select pine together with carpenter's glue and clamps.
Cut base and top
Using a table saw, rip a 4' x 4' sheet of 3/4" MDF to 20-1/2" and then crosscut to 32-1/2" for the base. For the top, crosscut the butcher block to measure 37-1/2" x 25-1/2".
Cut upper and lower surround pieces
On a table saw, rip 1 x 3 select clear pine to 2-1/2". Using a compound mitre saw, cut the lower sides at 36" and the upper sides at 46". Cut 4 end pieces at 23-3/8".
Using a 3/4" x 3/4" top-bearing mortising dado bit in a trim router and a router jig made from a piece of scrap 1 x 6 pine, dado the upper sides 5" in from each end to a depth of 3/8". Rabbet the lower sides 3/8" deep to accept the 23-3/8 ends.
Shape, cut and drill
On the sides of the upper surrounds, round the overhanging ends with a jigsaw and then use a 3/4" forster bit and drill to make 3/4" diameter holes, 3/8" deep. These will hold the 3/4" dowel for towel rack/handle on each end. Using a jig saw, cut an arch starting 9" from each end and 1" from top at centre to hide the 30" spaces that will be used to attach the butcher block top to cart.
Attach the lower sides to the MDF base with carpenter's glue and 1-1/4" 18-gauge brad nails. Attach the legs to the base surround with carpenter's glue and 1-1/2" #8 wood screws. Counter sink 2 screws to attach the MDF base to each leg. Glue and screw the two 30" x 2-1/4" spacers between the top of the legs with 3" #8 countersunk woodscrews. Glue the dowels and upper surround to the legs and spacers and countersink 1-1/2" #8 woodscrews to secure. Cover all exposed screw heads by gluing on 3/8" birch mushroom caps.
Using a router and 45° angle chamfer bit, finish the edges of the upper and lower surrounds, the bottom edge and outside of handles on the upper (but not the arches) and the corners and top edge of the lowers. Use a 1/4" roundover bit to finish the arches of the upper surround.
Fill and sand
Fill brad holes and any gaps with wood filler. Let dry, then sand with 120 grit sandpaper, followed by 220 grit.
Finish and attach butcher block
Oil the butcher block top with butcher block oil or boiled linseed oil and fix to cart by screwing through spacers. Countersink 1-1/2" #8 wood screws.
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Skill Level: Expert
Time: 2 days
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