Learn how to build a grill table to help you stay organized and keep everything close at hand when you are cooking outdoors. Now you can concentrate on the most important part - the food.
Make the Legs
Separate the 2-1/2-inch leg pieces into four pairs of two pieces each. Face-glue and screw each pair of leg pieces together to make four 1-1/2-inch-by-2-1/2-inch legs. In each leg pair, select the board with the least attractive face, and run the screws through that face into the other board. When you assemble the grill buddy, turn the legs so the screws face the inside of the assembly.
To avoid splitting the boards, predrill holes for the screws.
Assemble the FrameStep 1
Select two of the 23-3/4-inch-long pieces of 1 x 4 for the top-shelf end pieces and two for the bottom-shelf end pieces.
Measure down 2 inches from the top of each leg, and make a mark on the outside face and edge of each one. Use these marks to align the bottoms of the top-shelf end and side pieces.
Align the bottom of the top-shelf end piece with one pair of legs so that the end piece runs across the edge of each leg. The ends of the end piece should be flush with the outside faces of the legs. The bottom of the rail should be flush with the marks on the face of each leg. Screw the end piece to the legs.
Align and secure the bottom-shelf end piece. The bottom edge of the piece should be flush with the bottom end of the leg, and the ends should be flush with the outside faces of the legs.
Assemble the other two legs and end pieces using the first as a template.
Screw the 37-1/2-inch-long bottom-shelf side pieces to the legs. The ends of the side pieces should be flush with the outside faces of the end pieces. Use a combination square to square the frame.
Make a mark 1-1/2 inches in from one end and centered on the face of each 43-1/2-inch-long top-shelf side piece. Bore a 1-inch-diameter-by-1/2-inch-deep stopped hole centered on the mark. Use a jig saw or file to round the ends of the side pieces with the stopped holes. The end of the side piece with the hole will extend past the frame and the holes will receive the handle.
Screw one of the top-shelf side pieces to the frame with the hole facing the inside of the assembly. Insert the 1-inch dowel into the stopped hole, and screw the second top-shelf side piece in place. The dowel should rotate freely in place.
To give the project a more finished look, countersink the screws in the side and end pieces and add plugs or buttons to cover the holes.
Add Shelves and CastersStep 1
Screw the top-shelf side and end cleats (see image for representation of cleats) in place. The top edges of the cleats should be flush with the tops of the legs.
Use 3d finish nails to secure one 23-3/4-inch shelf floor panel at each end of the top shelf and three between them, spaced evenly.
Screw the bottom-shelf side and end cleats in place. The bottom edges of the cleats should be flush with the bottom edges of the bottom-shelf side and end pieces.
Notch two of the 23-3/4-inch shelf floor panels to fit around the legs for each end of the bottom shelf, and nail them in place. Install the rest of the floor panels.
Align the caster brackets so their outside edges are flush with the outside faces of the side and end pieces on the bottom shelf. Screw the brackets in place.
Screw the casters to the caster brackets.
Sand the entire assembly.
Apply two or three coats of exterior-grade varnish or polyurethane to the grill buddy.
Place the acrylic sheet on the top shelf.
Now you can cook with gas. Use pot holders or heat-resistant pads to protect the acrylic sheet from hot pots and pans.