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Weber Grill Cart

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Project by TheChucker posted 07-22-2010 05:13 AM 30086 views 17 times favorited 33 comments Add to Favorites Watch

I recently completed a grill cart for my Weber Grill that greatly improves the functionality I think. The actual grill gets dropped in this weekend and I’ll post a few more pics when that’s all in. Nothing new regarding the cart design, I actually modeled this design to one another member on here posted a few years ago and I think it turned out really well. The whole cart is made out of Cedar and sits on 3” double locking casters.

There are a million of these grill carts out on the internet for the Big Green Egg, but I just couldn’t find one for a Weber Grill. The difficulty with the Weber grill comes from the kettle contacting the wood cart, which is something to avoid. I did not want to have a tile top, which would have solved the problem, because I don’t think those look as nice. Too much country kitchen style for me personally. I eventually settled on concrete to provide a damper and sort of a heat sink between the grill and the wood.

I made a form for the concrete ring out of extruded polystyrene, poured in the concrete and let it cure. Following that, I mounted it to the grill cart with a ledge underneath. It now sits flush with the top and provides a small gap around the edge.

Overall, it turned out great and I look forward to dropping the grill in and firing it up. Thanks for looking.

-- Wherever you go, there you are.





33 comments so far

View ryno101's profile

ryno101

379 posts in 2330 days


#1 posted 07-22-2010 05:35 AM

I’ve had an idea about building one of these for years… this looks great! Nice work.

-- Ryno

View dan abalos's profile

dan abalos

106 posts in 1648 days


#2 posted 07-22-2010 05:55 AM

Nice work dude! I built one about 5 years ago from pine and stained it redwood. No gap for heat and it actually worked fine for us for all those years, I did get some “burning” of the wood but no real damage. I just got rid of it as I converted to gas, GASP! I do love the new grill but I miss some of the charcoal flavor it gave our meats.
Great work and cool idea for the concrete ring heat absorber.
~Dan

-- Beer is the reason I exist on this earth, that and my family! (Aurora, IL) my blog: http://justanaveragedad.wordpress.com/

View Greg..the Cajun  Box Sculptor's profile

Greg..the Cajun Box Sculptor

5142 posts in 1974 days


#3 posted 07-22-2010 06:14 AM

Toss on a few ribeye steaks and have fun…

View Joe Lyddon's profile

Joe Lyddon

7747 posts in 2717 days


#4 posted 07-22-2010 07:02 AM

COOL!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View Maveric777's profile

Maveric777

2691 posts in 1742 days


#5 posted 07-22-2010 02:42 PM

Yea! What Joe Said!...lol

Nice work….

-- Dan ~ Texarkana, Tx.

View johnnythegreat's profile

johnnythegreat

12 posts in 1538 days


#6 posted 07-22-2010 03:36 PM

Nice work, Chucker. Where’s the bottle opener? By the way, shoot Weber an email and offer to build these for them…

-- John, Minneapolis, "The juice is worth the squeeze"

View childress's profile

childress

841 posts in 2207 days


#7 posted 07-22-2010 05:15 PM

Nice…this is on my list of things to do and I was wondering about the heat problem also from the grill. Nice solution with the concrete ring. I am very curious how it’s going to hold up, my thinking is that being so thin, it will crack bad the moment heat is introduced. Can you keep us posted as to how it holds up? Thanks

-- Childress Woodworks

View TheChucker's profile

TheChucker

38 posts in 1778 days


#8 posted 07-22-2010 05:55 PM

Thanks for the comments. I’ll keep you posted on how the ring holds up to the heat. I think that it should hold up pretty well since a majority of the surface heat will be at the base of the kettle with the charcoal. The only metal actually touching the concrete will be the thin outer strip, but we’ll see. I figure if it held up well for Dan on a purely wood frame, the concrete should be OK.

Bottle opener will be installed soon John, the Guiness model is on order.

-- Wherever you go, there you are.

View Joe Lyddon's profile

Joe Lyddon

7747 posts in 2717 days


#9 posted 07-22-2010 06:05 PM

I’m curious about that too…

I’d also like to see the mold you used in making it… cement/sand mixture… plus any additives, etc.??

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View Dennisgrosen's profile

Dennisgrosen

10850 posts in 1780 days


#10 posted 07-22-2010 06:14 PM

great work on this cart
I have a weber and I wuold also like to here about the concrete ring
and if it hold up to the heat

Thank´s for sharing

Dennis

View DaddyZ's profile (online now)

DaddyZ

2404 posts in 1706 days


#11 posted 07-22-2010 07:28 PM

The only concern from myself, is the Cedar Wood, When it catches fire it is hard to put out or Control.

Ever thrown Cedar branches on a campfire, WOW !!!

The Idea alone is Great though, I have a webber & would like something like this with it.

-- Pat - Worker of Wood, Collector of Tools, Father of one

View TheChucker's profile

TheChucker

38 posts in 1778 days


#12 posted 07-22-2010 08:31 PM

Joe, the mold I used to make the ring was constructed out of extruded polystyrene mateial that they sell at Home Depot. It comes in pink 4×8 sheets. I made a circle mold in that and poured everything in. I tossed the mold out after I finished with it. I had to break it into sections to release the ring and it was worthless after that.

As for the mixture, it was just a standard concrete mix, all I did was add water. I put construction adhesive along the whole bottom side and along the lower outside to hold it all in place, along with some fireproof silicone material over that. That should secure the concrete enough that it won’t crack. If it does begin to crack at all, I could probably throw another skim coat over it with some patching material to true everything up again.

As for the cedar and its combustability, not really concerned. There won’t be an open flame anywhere to ignite the cart.

-- Wherever you go, there you are.

View MarkWilk's profile

MarkWilk

229 posts in 2541 days


#13 posted 07-26-2010 11:28 PM

The concrete lip is a great idea. I’ve been thinking of a way to build a small cart for my small Smokey Joe from Webber, and I think you’ve come up with a great solution. Good work.

-- Mark, Florida, http://penturner.wordpress.com/

View mcoyfrog's profile

mcoyfrog

3225 posts in 2259 days


#14 posted 08-02-2010 08:43 PM

nice job, the concrete is a great idea, thanks for sharing

-- Wood and Glass they kick (well you know) Have a great day - Dug

View rance's profile

rance

4135 posts in 1826 days


#15 posted 08-02-2010 08:58 PM

Nice cart. Great idea with the concrete. As an alternative, one could inlay a few river rocks in a ring for the pot to rest against, giving a much smaller(pinpoint) area of contact. Keep us posted, and post a pic with the Webber installed.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

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