My Grill Table Rebuild

[RickeyM]

I built a table for my kettle about four years ago and it's served me well, but it's showing it's age. Time and the elements have not been kind. I'm in the process of breaking it down and cleaning it up. Some of the wood pieces of the frame will have to be replaced. The top (deck) will get new wood too. I'm also adding larger wheels for easier rolling.
Work in progress:

 

[RickeyM]

The bottom deck planks are OK mainly because they've been covered with cement board. The kind of stuff you put on a bathroom floor before putting tile down. At first I was only going to replace only the lower frame rails but now I'll do top and bottom ones just because. Also I want to use threaded inserts and stainless steel fasteners this time. Originally I used lag screws which over time have a habit of loosening. Let's see if I can get eight years out of it this time.

 

[RickeyM]

My grandma, what big wheels you have.




The last time I cut the opening for the kettle with a jig saw. It was less than precise.


This is how you "stretch" a 36" board to match 46" boards.

 

[RickeyM]

Project "Over Engineering" is slowly coming along. Using a combination of oiled and Shou-sugi-ban treatments on the framing. Using both threaded inserts and pocket screws to join the framing together. Prior grill tables were just screwing some mainly scrap and reclaimed wood together. This one is actually planned out. I even made up a couple of jigs to put all the holes drilled in the framing in the right places.

 

[RickeyM]

For historical reference. Then (four years ago) and now (last week).

 

[RickeyM]

The top is screwed down and stained (1-coat) and the casters are mounted on the frame. It's pretty sturdy but I'm thinking of adding cross bracing to the framing.

 

[RickeyM]

I applied some wood stain (Teak) to the top a couple of days ago, but I put it on way to heavy so I had to go back and sand it off. Two steps up and one step back. I tried again yesterday using a sponge and contrary to instructions on the can, I thinned it a little. Because pine wood notoriously famous for not taking stain evenly, I'll wait another day before doing a light sanding. The bottom shelf of salvaged pallet boards, oiled for protection against the elements, was installed today. I'm thinking of maybe leaving the table's sides open.

 

[RickeyM]

Instead of having open sides I decided to use up some scrap wood I had laying around. Cut to size and a couple of coats of paint later.

A little light sanding and some Spar Urethane for the top.

Next I'll add some fold out shelves on the sides. At least one big enough to hold a Weber Smokey Joe

 

[Hajidub]

I can smoke better on an old Weber better than 99% of any BBQ I've ever tasted. Made ribs and chicken on it once, sons GF parents were visiting from Texas. I said, crap I should have made something else. The dad said he manages a big hitter BBQ place in Texas. Said he'd serve those meats in his restaurant over anything they served...LOL.