Cart - Barbecue Trolley .pdf - Projekty - stolarstwo - nisaczek

BARBECUE TROLLEY

192

Many of those odd bits and pieces required at the outdoor barbecue can be delivered conveniently on this

barbecue (or indoor tea) trolley. Basic design consists of two equal sized flat trays supported on corner

posts. However we strongly advise that you decide first on the sort of wheel/axle system since width of trays

should be made to fit closely between the wheels. With some changes in details the width of this barbecue

trolley can be adjusted to suit your purchased wheel, axle, bracket units. As an alternative you could use a

system of bolts and lock nuts, etc to fasten wheels to base tray or corner post as shown later.

TOOLS YOU WILL

NEED

MATERIALS YOU WILL NEED

• Saws

• Drill and bit,

countersunk

bit

• Measuring

tape/rule

• Carpenter's

square and

pencil

• Adjustable

spanner

• Wood chisel

• Hammer

• Screwdriver

• Chisel

Timber

Note that this trolley is designed on the

assumption that it will be generally protected

from exposure to rain and dew. If this limit on

exposure is accepted then standard door jamb

lining can be used (e.g. from Pacific Maple,

meranti, oregon, radiata pine, Tasmanian oak,

etc.) and standard or interior quality particle

board or plywood would be acceptable for

bottom of trays. Corner of posts could be timber

selected for appearance rather than for

performance under weather exposed conditions.

Hardware

• 8/50 x 6 mm

diameter

round head

wood screws

(end rail to

post).

• 40 mm x 6

diameter

round head

wood screws

(side rail to

post, handle)

• 100/50 x 2.8

mm bullet

head nails.

(bottom

planks)

• PVA wood

adhesive

• 2/150 mm

diameter

wheeels/axle

s bracket

units as

available.

• 50 mm x 50 mm DAR

4 pieces 750 mm * (4 posts)

• 100 x 38 mm door jamb lining (see

diagram)

4 pieces 900 mm * (side rails)

4 pieces 600 mm * (end rails)

• 100 x 25 mm DAR softwood

16 pieces as bottom planks or use 19 mm

particleboard or

12 mm plywood cut to fit frames.

• 75 x 25 mm DAR softwood

1 piece 900 mm * (rail bracket)

• 19 mm or 25 mm diameter dowel or

1 piece 700 mm for handle/rail

* Discuss these length requirements with

your supplier, who will supply standard

lengths of timber from which these pieces

can be cut.

Step by Step

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Cut corner posts

From the pieces of 50 x 50 mm DAR

timber cut four posts (P) each 750 mm

long.

Cut end rails

From the pieces of door

jamb cut four end rails (A) each of an

exact length to suit the axle/wheel system.

Example: For an overall width of tray of 500 mm cut four end rails each 465 mm long

Mark out side rails

At each end of the four side rail pieces mark out as shown 80 mm from each end. Mark edges as

guide for removal of excess material.

Saw and chisel out rail section

Saw and cut on marked line 80 mm from each end and chisel out excess materials to give four rails

as indicated in diagram. Check the dimension shown as 740 mm in diagram. This measurement

should be the same for each cut and trimmed rail.

Assemble tray frame

Fit tray rails together and fix in position using nails. Check squareness of trays and confirm that the

two trays are the same size. Trim rails and adjust where necessary.

Cut bottom planks

Measure internal width of tray as shown in previous diagram. Cut 16 bottom planks to this

length or cut particleboard or plywood to fit in as tray bottom.

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Square up trays

Fit a bottom into each tray and fix in place

using glue and nails. Before final fixing

square up tray and check that the two trays

are of the same size.

Attach legs

Fix trays to the four legs as shown in

diagram below using glue and screws. Note

that the final length of each pair of legs will

depend on wheel/axle bracket system used.

However, in this initial assembly, the four

posts

are of

equal

lengt

such

that

the

overa

heigh

t remains at 750 mm. The distance between trays

maybe varied depending on the wheel and axle

system chosen.

Fix wheel system

Note: The assembly could stand on four legs until the wheels are attached to the front of the

units, or the front 'legs' are removed first as appropriate for selected wheel assembly. Fit

selected wheel/axle system. Cut off excess front legs as required.

Provide drainage holes

If sheet products (particleboard or plywood) are used in trays, provide drainage holes (9mm

3/8" diameter in each corner. Loose fitted plank bottom if used should give adequate drainage.

Smooth and rounding off

Using sanding disc, sander or hand sanding or planing, smooth and round off all accessible

sharp corners and edges of the trays and posts. Punch all nails if desired and fill nail holes with

putty/filler the same colour as timber.

Note: The trays could have side rails projecting 5-10 mm beyond posts. These projections should be

rounded off thoroughtly, or trimmed off.

Cut, trim and fix handle

< From the piece of 75 x 25 mm DAR x 900 mm cut two handles each 450 mm long. Trim or

shape as in diagram, smooth all corners and edges, then screw - and glue-fix to rear end of

upper tray as in diagram.

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Note: To make sure that handle fits flat to the rail you may need to chisel out small pieces of the

handle where it comes into contact with the heads of screws into posts or use countersunk screws.

Cut to length and insert broom handle/dowel. Use glue in hole and drive in one 30 mm long nail

through top edge of shaped timber piece into handle/dowel.

Apply finishes

Clear finish with three coats of satin clear polyurethane finish, or selected stains, or garden

furniture finish or conventional paint finish. It is strongly recommended that the trolley receive

a thorough coating of one of these finishes and that this coating be maintained adequately.

For weather exposed trolleys

If the trolley is to be exposed to weather for long periods, then be selective about materials.

For timber components for example select 'durable' or moderately durable timbers such as

western red cedar, jarrah, black butt etc. or preservative treated timber, OR pay particular

attention to applying exterior finishes (and then maintenance) to low durability timbers.

Fastenings (nails, bolts, etc.) should be non-corroding such as hot dipped or electroplated

galvanised coatings.

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