Summer is the season of outdoor living — and there’s no better way to upgrade your backyard than with a custom-built bar or grill station. Whether you’re flipping burgers, mixing cocktails, or hosting family get-togethers, having a dedicated space for food and drinks can turn your patio into a true outdoor kitchen. Best of all, you can build it yourself using lumber, a few tools, and a weekend of your time.
Here’s a step-by-step guide for creating a stylish, functional outdoor bar or BBQ cart that’s perfect for summer entertaining.
Step 1: Choose Your Style and Size
First, decide which type of structure works best for your space and needs:
- Permanent Grill Station: Great for patios or decks with space to spare. Designed to house a grill and include prep space and storage.
- Portable BBQ Cart or Bar Cart: Ideal for smaller yards or renters. Lightweight and on wheels, this version can be moved or stored when not in use.
- Freestanding Bar Counter: A simple, stationary counter with stools — perfect for serving drinks and snacks.
Once you’ve chosen your style, sketch out a basic design. Most DIY carts or counters are around 36″ high, 24″ deep, and 48–60″ wide, depending on available space.
Step 2: Gather Lumber and Materials
Recommended Lumber:
- Frame: 2×4 pressure-treated pine (sturdy and moisture-resistant)
- Siding or Cladding: 1×6 cedar or shiplap boards for a polished finish
- Countertop: Exterior-grade plywood with tile or concrete finish, or sealed butcher block
Additional Supplies:
- Exterior wood screws
- Wood glue
- Caster wheels (for portable carts)
- Outdoor sealant or weather-resistant stain
- Hinges, handles, and hooks (optional for storage)
- Basic tools: drill, saw, level, tape measure, sander
Step 3: Build the Frame
Start by building a strong base using 2x4s. Create a rectangular frame for the top and bottom, then connect them with vertical supports.
For a cart, install locking caster wheels on each corner to make it mobile. For a stationary bar or grill station, use 4×4 posts if you want added stability.
Ensure all corners are square and the structure is level before attaching any siding or shelves.
Step 4: Add Siding and Shelving
Cover the frame with your chosen siding — cedar, shiplap, or tongue-and-groove boards add style and weather resistance. Install boards horizontally for a modern farmhouse look or vertically for a more classic feel.
Add shelves between the supports for storing condiments, cooking tools, paper towels, or beverage bins. You can also install towel bars, hooks, or a small cabinet for hidden storage.
Step 5: Create the Countertop
There are several countertop options depending on your skill level and budget:
- Concrete: Durable and heat-resistant, but heavy and best for permanent structures.
- Tile over exterior-grade plywood: Stylish and easy to customize.
- Butcher block: Beautiful and natural, but requires sealing with food-safe outdoor sealant.
- Stained and sealed cedar planks: A rustic option that’s simple and affordable.
Secure your countertop to the frame with screws and apply a waterproof sealant to protect it from rain, UV rays, and spilled drinks.
Step 6: Customize and Accessorize
Finish your summer station with personal touches:
- Add a built-in ice bin or cooler insert.
- Mount a bottle opener or hang a chalkboard drink menu.
- Hang string lights or attach a shade umbrella.
- Add bar stools, a grill tool set, and seasonal décor for full effect.
Enjoy Your Summer Setup
Once complete, your custom-built bar or grill station will be the go-to spot for all your outdoor gatherings. Built from sturdy lumber and tailored to your space, it’s a project that adds serious style and function — and creates a summer full of sizzle, smiles, and cold drinks.
Need help picking the perfect wood or supplies? Visit Friel Lumber for expert advice and everything you need to bring your backyard vision to life!
