Detailed Steps On Making Outdoor Patio Cooler Cart:

1. Cut the eight long and short leg pieces to length.

2. Apply a bead of glue to one long edge of each end leg, and then clamp each leg to a mating front or back leg. Drive 1-1/2″ finish nails through the front or back legs to secure the joint.

3. Cut the front, back and end panel boards to length. Apply a bead of glue to each edge and clamp the boards that make each panel.

4. Position the tops of the panels flush with the top of the legs and attach the panels to the legs with 1-1/4″ exterior-rated screws. Predrill 1/8″ pilot holes to prevent splitting the boards near the edges or ends. We chose to use finish washers to add a decorative element, but you could also countersink each screw (photo 2).

5. Cut the bottom supports to length and attach them5. Cut the bottom supports to length and attach them to the bottom of the panels with 2″ screws.

6. Cut the axle support blocks to length and attach them to the inside face of the front and back short legs. These blocks are flush with the bottoms of the legs.

7. Bore a 5/8″-dia. hole through the front and back legs and axle support blocks. The center of these holes is located 1-1/2″ up from the bottom of the leg.

8. Cut the axle to length with a hack saw.

9. Insert the axle through the axle holes. Place one flat washer over each end of the axle. Place the one wheel on each end of the axle. Then secure each wheel with a 1/2″ push nut. Use a hammer to pat the push nut on the axle.

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