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| These compressed wood "biscuits" fit perfectly into the slots cut by the plate joiner. |
Press the biscuits into the slots. Use a small paintbrush to spread any excess glue onto the flat wooden surfaces adjacent to the slots. This will help to make a stronger bond.
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Press the slats into place. From this angle, it's easy to see how the biscuits keep everything aligned. |
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| Cut slots in the top back, and squeeze glue into the slots in the other side of the rails. Press biscuits into the rails and spread the glue with a small brush. Insert glue in the slots on the top back and slide it into place. |
A series of bar clamps, alternating between the top and bottom, will hold the top together as it dries. |
In a few hours, remove the top from the clamps and using a random orbit sander, eliminate any ridges or dried glue, making the surface smooth to the touch. Be sure to sand with the grain of the wood. |
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| Next, use a router with a roundover bit to machine a 3/8" radius around the edge of the top. Then do your finish sanding with a palm sander and 150 grit paper, remembering to sand with the grain. |
On the underside of the grill station top, place a pair of 23" long 1x4 support slats across the gap. These slats will hold the cutting board in place. Drive these into place with weatherproof screws. |
Now that t he top is finished and the base is just about finished, it's time to join the two pieces together.
Once again, countersunk pilot holes and three-inch weather resistant screws will do the trick. |
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| This paper towel rack is made of three pieces that should be familiar by now: a pair of 5" 2x2s, with a 3/4" dowel run through a 3/4" hole on one rounded end of each of the 5" pieces. Attach the square ends of the towel rack supports to the frame under the front rail with weather-resistant screws. |
A simple cedar box makes a great condiment tray, which can be attached to the short side of the prep station that is farthest from the handle. Be sure to drill drainage holes in the bottom of this tray to protect it from the elements. After staining, hooks may be attached to the face of this box for your BBQ utensils. |
Assembly is now complete! It's
time to protect your grill station from the elements.
A thorough shaking insures that the color pigments in
this combination
stain/sealer get evenly distributed. Before starting,
pour the finish into a container small enough to hold
in your hand. |
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| Using a natural bristle brush, brush with the grain using long, straight strokes to work the finish well into the surface. Begin at the top and work downward to catch any drips as you go. |
A stain
sealer like this one does several things. It helps
keep water from penetrating the wood fibers. Its UV inhibitors
protect against fading, while a protective coating resists
mildew and discoloration. Finally, tinted stains add color
to the wood, evening out variations in tone and shape.
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Well, I think I got just about everything I wanted. Paper towels close at hand, a cooler within easy reach, grilling tools at the ready and condiments where I can get my hands on them. Everything a guy could want in a grilling prep station. Well, plus maybe a couple of sirloins. |
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