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Build this serving station as an outdoor entertaining center, or turn it into a kitchen island for loads of storage and work space. Sturdy, easy-to-assemble pipes support three cedar shelves.
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We created the top and shelves using cedar. You can also substitute oak, poplar or pine.
For the top, cut four 1 x 8 boards 47-3/4 inches long. Place the boards side by side and measure their combined width. Then cut two 1 x 8 end boards that length (about 29 inches). Glue and clamp the end boards to the four top boards (Serving Station Shelves Project Diagram, Drawing 1).
Cedar boards have a rough face and a smooth one. Before assembling your top and shelves, decide which look you prefer on the outside.
Measure between the inside edges of the two end boards and cut 1 x 2 boards that length. Glue and clamp them between the end boards with the edges flush with the top board edges. Apply the finish of your choice or leave unfinished as shown.
The middle and bottom shelves are identical except for an extra set of holes in the bottom shelf (Serving Station Shelves Project Diagram, Drawings 2 and 3). Begin by cutting eight 1 x 8 boards 47-3/4 inches long for both shelves. As with the top, measure the width of four boards side by side and cut 1 x 4 end boards to length. Glue and clamp the end boards to the four top boards for each shelf. Cut the edge boards to length from 1 x 2 boards and glue them in place for both shelves.
Using a 1-1/4-inch hole saw, drill six holes for the bottom shelf and four holes for the middle shelf where shown (Serving Station Shelves Project Diagram, Drawings 2 and 3). Apply the optional finish of your choice.
From 3/4-inch pipe, cut the following pieces: two at 38 inches, one at 25 inches, four at 24 inches, two at 20-1/2 inches, one at 20-1/4 inches and two at 15-1/2 inches. You’ll use the entire length of the eight 36-inch pipes. File the ends as needed to remove any sharp pieces of metal.
By cutting the pipes in order of longest to shortest, it’s easier to salvage any pieces accidentally cut to the wrong length. Simply recut them to the next shorter size for minimal waste.
On four 36-inch pipes, fasten a flange to one end. Then slide a 3/4-inch combination socket down each pipe to rest loosely against the flanges (Serving Station Pipe Assembly Guide, Drawing 1).
Slide a three-socket tee onto a 36-inch pipe and connect it to two of the legs. Repeat for another 36-inch pipe. Then connect the two pairs of legs using 24-inch pipes. On both loose tees, attach a 15-1/2-inch pipe. Tighten the tees in place so that the 15-1/2-inch pipes fit the center holes in the bottom shelf.
Assemble the pipes and fittings on a flat, level surface to reduce the chance of the finished server wobbling.
Carefully lower the bottom shelf down the legs and 15-1/2-inch pipes until it rests on the base.
Attach a 20-1/4-inch pipe to an adjustable side outlet on one end and a 90-degree side-outlet tee on the other. Then attach a 25-inch pipe to the side-outlet tee and add a single-socket tee to the opposite end. Slide the assembly down a pair of legs and one center pipe as shown (Serving Station Pipe Assembly Guide, Drawing 2). Fasten it in place level and 5-1/2 inches above the bottom shelf.
Slide two 3/4-inch hooks and a three-socket tee loosely on a 36-inch pipe and fasten two 3/4-inch combination sockets to the ends. Repeat for a second 36-inch pipe, then connect the two assemblies using a pair of 24-inch pipes. Lower the assembly down the legs of the server, slip the tees into the tops of the 15-1/2-inch pipes and fasten the assembly in place 13-1/2 inches from the bottom shelf. Adjust the front and back pairs of hooks and fasten them in place. Lower the middle shelf down the legs to rest on the pipes and fittings.
Fasten adjustable side outlets to the ends of a 38-inch pipe. Slide two hooks onto a second 38-inch pipe and add adjustable side outlets to the ends. Slide two rail supports onto a 28-inch pipe and fasten adjustable side outlets to the ends. Repeat for a second 28-inch pipe. Slip the end pipes and the front and back pipes onto the legs, arranging the adjustable side outlets to stack on top of each other as shown.
When the side outlets are properly combined and adjusted, the front, back and side pipes will rest even with each other.
Slide the adjustable side outlets on the horizontal pieces up to the tops of the legs and fasten them in place. Use a long, straight board to check that the tops of the rail supports are level.
Center the top on the rail supports and mark the positions of the mounting screw holes. Drill 1/8-inch pilot holes and screw the top to the supports with #10 x 1-inch panhead screws.