DIY - Butcher Block Kitchen Cart

11:13 AM


I have a tiny kitchen with not a lot of counter space.  Also - because my kitchen has 3 doorways I've been dying to block one of the doors to cut down on foot traffic when i'm cooking.  This little cart solved both problems!

I did a LOT of research online  and decided to build one of 3 carts.  Here were my options.

Option #1
I love the design of this choice, but I could not find the part to make the cart pictured.


Option #2
This seemed easy enough to build but I needed to complete the project quickly.  

Option #3
This option seems simple and functional and would not take a lot of time to assemble, so it because my choice!

The cart I built was basically an inexpensive rolling cart with a butcher block top.  I found the cart at both Home Depot and Lowes for $19.99.  The weight limit on my cart is 160 lbs which was more than enough for my needs.  There is another version with a limit of 750 lbs for the same price.  


I purchased 1 wooden plank that was 2x10x6.  I had the wood cut into 3-30" pieces.  Next I lined up the planks in the order that I wanted them for my cabinet top.



Using a kreg mini jig I drilled pocket holes in the planks.  I'd never made pocket holes before and I was kind of afraid of the process.  I watched a couple of videos on you tube, read the directions and it was no big deal.





I drilled 3 holes in each plank of wood


Put gorilla wood glue between the planks




Screwed them together.

The completed counter top was slightly bowed and I don't have any clamps that are the proper size.  So I put the completed piece outside and put heavy rocks on top until the glue was completely dry.


While the glue dried I assembled the metal cart.  I had forgotten to get hardware to attach the top so I ran back to the store.




There was no ready made screw or clamp that did exactly what I wanted it to do, so I improvised.  To attach the counter top I used 2 3/32" - 1/8" wire rope clips.  These were in the same aisle as rope.  In the hardware aisle I found screws that would work.

Wire Rope Clip
  
Disassembled Clip

Upside Down Clip


Installing the clip

Works perfectly!
I used 4 clips to hold the counter top in place.


I filled any cracks in the wood and allowed the filler to dry.


Using a palm sander I sanded the wood until it was VERY smooth and even.  I wanted to lightly stain and seal the wood, so I used a cloth to rub on a little bit of light walnut stain that was left over from another project. 


Staining the wood made the seams much less visible.

Stained Wood

Once stained, I allowed the wood to dry overnight.  Them finished it off with a coat of Howard's Feed and Wax.  It gave the wood an amazing smell and a nice shine.


I LOVE how this project came out.  It took longer than I thought it would (overnight drying time), but all in all i'm very happy with the results.

The original cart was $139.00 on clearance at Overstock.com.  My version was about $50.

Everything came from Home Depot:

1-                 Cart                      $19.99
1-2x10x6     Wood                    $ 7.91
1 box            Pocket Screws      $5.88
1 pkg -          Screws                  $1.88
1 pkg -          Wire Rope Clips   $  .97
1 bottle   Howard Feed & Wax  $7.99
1 tube     Wood fill                     $7.99
----------------------------------------------
Total Cost                               $52.61

I already had the following items:  Wood Stain, kreg mini jig

Also, I didn't want or need wheels for this project.  I costs about $20 to add wheels.  Since I didn't need them, I left them off.

Here are a few action shots!









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