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Project by mattsanf posted 07-24-2007 04:28 PM 3350 views 18 times favorited 21 comments Add to Favorites Watch

This is hardly “fine” woodworking…this is more summer “fun” woodworking. I will post some of my more serious woodworking projects later.

My wonderful family got me a great combination birthday/father’s day gift this year… A Kamado-style ceramic grill/smoker from “Primo” Grills and Smokers (similar to the better-known Big Green Egg Brand cookers). I have long enjoyed grilling, and as my wife says “The ceramic cooker should allow for many hours of your obsessive tinkering and experimentation”....she knows me well.

First order of business, of course, was to combine my hobbies and build a cart for the smoker. See photos above.

More on my blog at:

This was a simple but fun project that gets used a lot!! Since the smoker’s body is VERY thick ceramic, it is VERY heavy. 200-250 pounds, I believe. So, this stand was built to be strong rather than pretty.

The cart is made from standard pressure-treated lumber for the legs and the horizontal structural components and Trex-brand composite decking for the shelf and top surfaces. Since Trex cannot support much weight, the pressure-treated lumber was necessary for the structural components. As a woodworker, I cringe at the use of materials like Trex, but I must admit that they do have their place.

I used concrete pavers under the grill to protect the decking material from heat. The rear wheels are replacement solid-rubber “handcart” wheels. The front wheels are industrial-rated swiveling casters.

The photos don’t show it, but the cart also has a mount for a beach umbrella to shade the bald cook from the sun. With my wife’s multi-colored umbrella in place, I must admit that the smoker cart looks a bit like a hot dog stand.

A side mounted beer opener completes the project.

Now back to your regularly scheduled “real” woodworking…


-- -- Matt Sanfilippo, Pittsburgh, Pa.,

21 comments so far

View CharlieM1958's profile


16143 posts in 3311 days

#1 posted 07-24-2007 04:42 PM

Great idea! I love this thing.

I’m wondering if I could do something similar with my plain old Webber kettle grill…

-- Charlie M. "Woodworking - patience = firewood"

View mattsanf's profile


34 posts in 3056 days

#2 posted 07-24-2007 05:03 PM

Thanks! I’m sure that you could. It makes it much easier to cook at a better “working” height.


-- -- Matt Sanfilippo, Pittsburgh, Pa.,

View Aubrey's profile


43 posts in 3064 days

#3 posted 07-24-2007 06:09 PM

What a great idea!

I have a smoker/gril that I enjoy but don’t use it that much due to the lack of height.

Now I have a way to solve that problem.

Thanks Matt!


-- Jesus was a Jewish carpenter.

View MsDebbieP's profile


18615 posts in 3253 days

#4 posted 07-24-2007 06:41 PM

sure looks like a fine job at woodworking, to me!! Boy, if I made something like this, everyone would surely be impressed.

-- ~ Debbie, Canada (

View Bill's profile


2579 posts in 3254 days

#5 posted 07-24-2007 06:43 PM

Sniff…Sniff….ok so where is that BBQ dinner we were waiting for? haha…Nice looking cart Matt.

-- Bill, Turlock California,

View jockmike2's profile


10635 posts in 3339 days

#6 posted 07-24-2007 07:03 PM

What a gas for the summer time blues. Great idea and good wood work. jockmike

-- (You just have to please the man in the Mirror) Mike from Michigan -

View Drew1House's profile


425 posts in 3180 days

#7 posted 07-24-2007 11:38 PM

Nice work… I must say that when I was looking for decking material I almost went with Trex… then last minute switched to Ipe… I have been very pleased both with the look and durability (4 times the density of oak)... my deck is like a peice of furniture.


-- Drew, Pleasant Grove, Utah

View Don's profile


2603 posts in 3269 days

#8 posted 07-25-2007 01:03 AM

Nice project. Must be a beast to move around the yard. Sorry to hear your wife is going bald! LOL

-- CanuckDon "I just love small wooden boxes!"

View Bob Babcock's profile

Bob Babcock

1804 posts in 3178 days

#9 posted 07-25-2007 04:25 AM

I tip my hat to any man that has a bucket buddy for his BBQ tools. You are the man! Very nice setup.

-- Bob, Carver Massachusetts, Sawdust Maker

View Karson's profile


34994 posts in 3493 days

#10 posted 07-25-2007 06:25 AM

Is the next LumberJocks picnic at your place?

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View cajunpen's profile


14538 posts in 3158 days

#11 posted 07-25-2007 09:46 AM

Nice project Matt. What are your thoughts on the cooker itself. I’ve been thinking about getting one of the Green Eggs – how do you think it compares?

Also, good eye Bob, noticing the Bucket Buddy – you don’t miss much do you :-))

-- Bill - "Suit yourself and let the rest be pleased."

View oscorner's profile


4564 posts in 3403 days

#12 posted 07-25-2007 05:13 PM

Nice job! Do you find the front wheels adequate? Do they sink into the ground under all that weight?

-- Jesus is Lord!

View mattsanf's profile


34 posts in 3056 days

#13 posted 07-25-2007 10:03 PM

Thanks Folks!

Yes, it is a beast to move around the yard, and so I don’t move it much. Only when necessary. It is HEAVY. Luckily, my yard is flat, or this thing would not be rolling anywhere.

and yes…the front casters do sink into the ground. If I changed one thing about my design, it would be different (larger) casters on the front. The rear wheels are fine.

The bucket buddy has worked out very well for grill tools. It is deep enough to hold long things like tongs or grill forks, and is easy to carry everything back into the house in one shot. It was my wife’s bucket buddy for the garden, but I noticed that it wasn’t getting much use…and so I “borrowed” it (permanently).

As to the Primo-brand grill itself, I love it. It is very similar to the Big Green Egg, only larger. I think that you cannot go wrong with either one, but because this one is oval shaped rather than round (like the egg), it holds slightly more. Plus, the Primo is made in the USA…which is nice.

-- -- Matt Sanfilippo, Pittsburgh, Pa.,

View NormiteLou's profile


36 posts in 3065 days

#14 posted 07-26-2007 02:51 PM

Great Job! I gotta do one for my Webber!

-- Normite Lou

View RobS's profile


1334 posts in 3399 days

#15 posted 08-01-2007 10:17 PM

Very cool, I had no idea that those things were that heavy. Are you concerned at all about too much heat around the middle where the Grill goes through the Trex?

-- Rob (A) Waxahachie,TX

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