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How to build a D.I.Y. kitchen trolley

By Bunnings Magazine /

Kitchen trolley with pots, bowls and tea towel in modern kitchen

Overview

Most kitchens benefit from a little extra preparation room. This freestanding bench is a useful addition to any space-challenged kitchen. Don’t be put off by the woodworking. We’ve used lightweight, easy-to-work-with pine, notching the legs to make recessed joints using a mitre saw and chisel. If yours aren’t perfect, just fill and sand around them before painting. For the top we selected a timber panel with a food-safe finish.

Tip: Always use a chopping board when preparing food to avoid damaging the timber panel.

Safety tip: Always wear the appropriate safety equipment (safety glasses, ear muffs and a mask, for example) and always follow the instructions for the product or equipment.

Steps

  1. 1

    Measure and cut all the pine pieces to size

    Using a mitre saw, cut four 880mm legs from 42mm-square pine. From 42mm x 19mm pine, cut four 385mm end rails and four 1180mm side rails. From the 1800mm x 405mm panel, cut a 1260mm top, plunge-cutting from one side then flipping the panel to finish the cut from the other.

    Green Bunnings hammer
    Tip: The shelf and backing are 1200mm x 300mm panels.
    Mitre saw cutting a piece of pine.
  2. 2

    Make recessed joints for the side rails 

    On each leg, use a pine offcut to mark 42mm down from the top and a combination square to mark 10mm along the sides of the joint. On the same face, 150mm up from the base, mark either side of the offcut and 10mm along the sides.

    Green Bunnings hammer
    Pro tip: If you’re not confident making the recessed joints, subtract 20mm when cutting the side rails to be 1160mm long, then butt-join the end rails to the legs with adhesive and screws.
    A person uses a combination square to measure and mark a piece of pine.
  3. 3

    Chisel out the recessed joints

    Set the saw to cut 10mm deep, using an offcut as a test, then make close cuts within and along the marks. Clamp the legs to clean joints with a chisel.

    Green Bunnings hammer
    Tip: To ensure the blade makes the full cut, position an offcut against the saw fence, with the leg firmly against it, waiting for the blade to stop before moving it each time.
    Person chisels into a piece of pine.
  4. 4

    Make the end frames

    Set out the legs, with the recessed cuts facing up. Apply adhesive and then position the end rails straight and flush with the sides. Prevent splitting by pre-drilling two holes into each with a combination countersinking bit, securing with 30mm screws so the heads sit below the surface.

    Frame of a kitchen trolley constructed from pine.
  5. 5

    Secure the legs and side rails

    Clamp the end frames sideways, positioning the front side rails between them, against the legs and lined up with the top and base rails. Secure with adhesive and screws into the legs.

    Green Bunnings hammer
    Tip: Attach one set of top and base rails, then flip the assembly to attach the other.
    Frame of a kitchen trolley secured with screws.
  6. 6

    Install the shelf panel

    Position the shelf panel over the base rails, with even gaps at the ends of about 10mm. Pre-drill and countersink holes through the panel, securing into the rails with 30mm screws. Position the backing panel 100mm up from the shelf, flush with the sides of the legs, pre-drilling and securing with screws.

    A person securing a shelf panel to a kitchen trolley pine frame using a drill.
  7. 7

    Fill, sand and apply water-based enamel paint

    Sand the frame with 120-grit abrasive paper, removing screw breakout and rounding over the edges. Fill the screw heads with timber filler, leaving to dry. Sand the frame with 180-grit abrasive paper, wiping away dust with a damp cloth. Apply two coats of water-based enamel paint with a brush, leaving to dry after each coat.

    Green Bunnings hammer
    Tip: Using a water-based enamel to paint the bench frame adds a tough finish that is more resistant to dents and scratches in this high-traffic area.
    A person uses timber filler to fill the screw heads in a timber frame.
  8. 8

    Secure the top and frame with angle brackets

    Position the top and frame upside down, with the backs flush and an even 20mm overhang on the sides. Evenly space two angle brackets along each side, securing into the top and rails with 15mm button head screws. Use a 4mm bit to pre-drill and attach pull handles to the top end rails.

    Angle brackets drilled into a kitchen trolley top and frame.
  9. 9

    Sand, clean and apply food-safe benchtop oil

    Sand the cut end of the top with 180-grit abrasive paper, rounding over the edges and corners to match the rest of the panel, then wipe away dust with a damp cloth. Touch up the finish by using a clean cloth to apply food-safe benchtop oil over the raw edge, wiping away excess and leaving to dry.

    *Timbers vary by state and territory, contact your local store for further information.

    A person using 180-grit abrasive paper to sand and finish a timber kitchen trolley top.

    Keep in mind:

    • Always ensure the finish you use on D.I.Y. timber kitchen furniture and accessories is food safe.

  10. 10

    Prefer a raw and industrial look?

    Take a look at our step-by-step guide to building a wood and concrete kitchen island.

     

    Photo Credit: James Moffatt and Natasha Dickins

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Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.