Materials
- 3″ Simpson Strong-Tie® Deck-Drive™ DSV Wood screws
- 2 1/2″ Simpson Strong-Tie DSV Wood screws
- Cedar 2×6 boards for the top
- Treated 2×4 lumber for the base
- 2″ locking casters
- Double utility hooks
- Outdoor stain and finish
- Counter-height stools
Deck-Drive™ DSV WOOD Screws
Tools
- Miter saw or circular saw
- Drill or driver
- Tape measure
- Clamps
- Sander and sandpaper
- Finishing supplies
Jamison recently DIYed a Simpson Strong-Tie® Sage System™ pergola for a friend’s smoker setup, but once the smoker was placed under the new structure, he realized the area felt empty and lacked workspace. He wanted a piece that could function as both a grilling station and a dining table without overwhelming the small concrete pad. A rolling cart with a cedar top and treated lumber base offered the perfect solution.
To maximize functionality, he designed the cart to serve multiple purposes. It would provide prep space beside the smoker, double as a counter-height dining table, and store stools neatly underneath. This allowed the area to stay tidy while offering more room for food prep, serving and hanging out.
For the top, Jamison selected cedar because it naturally resists rot and insects while offering a clean and durable surface. He used 8′ 2×6 boards, cut them in half, and laid them out to form a 33″-wide work surface. After sanding, each board received a protective finish before assembly.
The base was built from treated 2×4 lumber for long-term durability. Jamison cut all pieces to size using his detailed cut list and stained them to create contrast with the cedar top. Assembly began with the frame that would support the top, followed by a center stringer for stability.
Simpson Strong-Tie DSV Wood screws were used for all structural connections. Jamison chose the black-coated screws so they would blend into the stained lumber and provide strong, clean fastening.
To make the cart easy to move around the patio, Jamison installed 2″ locking casters. These casters lock both the wheel and the swivel movement, keeping the cart steady during use. He drilled openings for threaded inserts, installed the casters, and flipped the cart upright to continue building.
With the base complete, Jamison centered the cedar boards on the frame and prelaid the screw positions for crisp alignment. He used black Simpson Strong-Tie screws for a clean contrast and installed them carefully, so each head sat flush with the cedar surface. The completed top created a sturdy counter-height workspace ideal for prepping food and placing trays near the smoker.
To keep stools out of the way when rolling the cart, Jamison created a clever under-table storage solution. He built small T-shaped cleats that mounted to the underside of the top. Utility hooks attached to these supports allowed the stools to hang neatly below the counter while metal rests held the stool legs in place.
After testing various hook types, he found that rubber-coated utility hooks provided the best grip and minimized noise. This simple addition helped keep the cart compact and clutter-free.
While the top and base were drying, Jamison returned to the pergola with an idea to make the grilling area even more functional. He added a long shelf between the pergola posts, capped with deck boards, creating a buffet-style workspace perfect for setting out food or grilling tools. He also added the Simpson Strong-Tie Sage-Shade™ sunshade to the top of the pergola. This was a great way to create more shade from the backyard sun during the warmer months.
This project brought together smart design, practical storage and durable materials to create a grilling cart that could make a great outdoor space even more enjoyable. By pairing a cedar work surface with a sturdy treated-lumber base, adding smooth-rolling casters with brake-locks, and integrating clever stool storage, Jamison delivered a versatile piece that functions as both a prep station and a dining table. Combined with the new pergola shelf and added shade, the entire grilling area now feels more intentional, more comfortable and ready for countless backyard gatherings.
Jamison continues to show how thoughtful DIY projects can completely transform a space. Whether it’s improving workflow around a smoker or simply creating a place to sit and relax, he proves that good design and strong fastening solutions make all the difference. Until the next build, happy building happy grilling!
See the full project unfold on Jamison’s YouTube channel.
