How to Make a Cart for a Weber Kettle

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An outdoor grill allows you to quickly serve meats, vegetables and other grilled foods at backyard gatherings and social events. Kettle grills, such as Weber's line of kettle grills, help you prepare foods without heating up your kitchen. Some of the larger kettle grills are unwieldy and difficult to move. Building a cart for your Weber kettle grill lets you easily move the grill to your garage or shed, protecting it from rain and snow.

Things You'll Need

  • Measuring tape
  • 2-by-4-inch pressure-treated lumber
  • Circular saw
  • Power miter saw
  • 4-inch wood screws
  • Drill
  • Screwdriver bit
  • 3/4-inch-thick plywood
  • Table saw
  • 1-by-2-inch pressure-treated lumber
  • Polyurethane sealant
  • 2-inch paintbrush
  • 4-inch swivel casters
  • Measure the kettle grill's base’s dimensions with a measuring tape. The cart’s top should be at least 4 inches larger than the grill’s base, keeping the grill from tipping over during grilling or transport.

  • Cut two sections of 2-by-4-inch pressure-treated lumber the width of the grill cart with a circular saw. Cut an additional two sections the cart’s length. Miter the ends at 45-degree angles with a power miter saw.

  • Assemble the length and width sections into a rectangle. Drive 4-inch wood screws through the corners with a drill outfitted with a screwdriver bit.

  • Measure the rectangular frame’s interior width. Cut one section of 2-by-4-inch pressure-treated lumber to this measurement for each 8 inches of cart length. Place these sections inside the rectangle at 8-inch intervals, and then drive 4-inch wood screws through the rectangular frame into the ends of these supports.

  • Cut a section of three-quarters inch thick plywood with a table saw to fit the rectangular frame’s outer dimensions. Place the plywood section on the frame and align the edges. Drive 4-inch wood screws through the plywood into the frame at 4-inch intervals.

  • Cut two pieces of 1-by-2-inch pressure-treated lumber to the cart’s width and an additional two sections to the cart’s length. Miter the ends at 45-degree angles and assemble the sections on top of the plywood flush with the outer edges. Attach these sections with 4-inch wood screws at 4-inch intervals. This creates a lip that helps keep the grill from rolling off the cart.

  • Apply polyurethane sealant to the plywood, lip and frame sections with a 2-inch paintbrush. Let the sealant dry for six hours, and then apply a second coat.

  • Turn the cart top over, so that the frame is on top. Position a 4-inch swivel caster on each corner of the frame. Drive 4-inch wood screws through the holes in the caster mounting bracket into the frame.

Tips & Warnings

  • Wear work gloves and eye protection when cutting and assembling the grill cart.

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