DIY Outdoor Bar, Drinks Trolley
How do you build an outdoor drinks trolley or bar cart?
This is a timber-framed cart on wheels, sized to hold an esky or a sink, glued and screwed together and finished with a clear exterior varnish. The build is: make two identical side frames, join them with rails top and bottom, screw timber slats across the base and either side of the sink, add wheels, plug the countersunk screw holes with dowel, then sand and coat. Every timber joint is glued with Selleys Aquadhere Exterior as well as screwed.
The dimensions used here are 900 mm high and 1600 mm long, but the design is not fixed — make it the size that suits your space, and set the internal width to match the sink or esky you intend to drop into it.
What you need
- Selleys Aquadhere Exterior
- Timber for legs, rails and slats
- Batten screws
- 16 mm timber dowel
- 16 mm spade bit and a 4.5 mm drill bit
- Drop saw or circular saw
- Drill
- Wheels and axle
- Sink or esky
- Sandpaper
- Cabots Clear Exterior Varnish, or your chosen oil
- Wet cloth for clean-up
Why Aquadhere Exterior and not an interior wood glue
Aquadhere Exterior is an industrial-grade polyaliphatic cross-linking PVA developed for professional woodworkers. It produces bonds stronger than most woods and is weatherproof, which is the entire reason it belongs on a cart that will live outside. It is ideal for dowelling, joinery, laminating, veneering and cabinet and furniture making, and it will stick softwoods, hardwoods, particleboard, chipboard, plywood and MDF. It can be chiselled, routed or turned once cured.
| Technology | PVA |
| Colour | Off-white, dries clear with a yellow tinge |
| Coverage | Approximately 5 m²/L |
| Clamp time | Softwoods 30 minutes; hardwoods 1 hour |
| Maximum bond time | 24 hours |
| pH | 2–3 |
| Viscosity | 2000–3500 cP |
| Packaging | 250 mL, 500 mL, 1 L and 4 L bottles |
Indicative data only, not intended for preparation of specifications.
By contrast, Aquadhere Interior is interior-only, is not waterproof, and is not for structural use. It is the wrong glue for anything that goes outside, however good the varnish on top.
What the figures mean for this build
Clamp for 30 minutes on softwood and an hour on hardwood, and do not stress the joint for 24 hours. On this cart the batten screws are doing the clamping, so the practical reading is: glue and screw a frame, then leave it before you start hanging weight off it. Maximum strength is attained in 24 hours, but longer in cold, damp conditions or with dense timbers.
Apply the adhesive liberally to one surface only. That is what the data sheet specifies. Gluing both faces of a joint wastes glue and gives you more squeeze-out to clean up, not a stronger bond.
Wipe excess off with a damp cloth while it is still wet. Cured PVA on a timber face will not take stain or varnish evenly, and it shows as a pale patch. Anything you miss can be sanded off once dry.
How to build it
- Measure and cut. Set out the overall size — 900 mm is a good height and 1600 mm a good length. Make one side frame first: cut two legs or posts 900 mm long, and two rails 1600 mm long, using a drop saw or circular saw.
- Fix the frame together. Use batten screws and Aquadhere Exterior for extra strength. Make the top rail flush with the top of the posts and set the bottom rail 150 mm up. Mark the screw positions — two at each join — countersink with the 16 mm spade bit, then pre-drill with the 4.5 mm bit. Apply the adhesive to the end grain of the rails and drive in the batten screws. Wipe any excess glue off with a wet cloth; anything you miss can be sanded once dry. Then make a second identical frame for the other side.
- Cut the connecting rails. Decide the internal width of the cart — matching it to your sink or esky is the sensible approach. Cut four rails to that width, apply Aquadhere Exterior to their ends, and connect the two frames together, fixing the top two rails flush with the top of the legs and repeating for the bottom two. The frame is now complete.
- Slat the base. Measure the overall width and cut timber slats for the base. Screw them down into the lower rails across the base of the trolley to give a solid platform for storage.
- Create bench space. Repeat the slatting either side of the sink or esky to make usable bench surfaces.
- Add the wheels. Screw the wheels and axle into position at one end of the cart.
- Plug the screw holes. Cut short pieces of 16 mm dowel to plug the countersunk batten screw holes, leaving them slightly proud. Apply Aquadhere Exterior to the inside of each countersunk hole and insert the dowel plug — you will see glue ooze out the sides, which is how you know the hole is full. Wipe the excess with a wet cloth. Once the glue is set, sand the dowel flush.
- Sand and finish. Sand the whole cart, removing splinters and pencil marks, dust it off, and apply a varnish or oil.
Limitations — what Aquadhere Exterior will not do
- Not recommended for joints subjected to constant high stress. On this cart the screws carry that; the glue adds strength and keeps the joints tight.
- Not suitable for below-waterline applications or continuous submersion. Weatherproof is not the same as immersed — keep the cart out of standing water.
- Avoid contaminating the adhesive with iron and steel — nails, for example. Aquadhere will stain a brown or black colour if contaminated with rust (iron oxide), or in the presence of the tannins found in many woods. That is worth remembering if you are building in a hardwood.
- Surfaces must be close fitting, dry and clean. Ensure the surface is dry before applying the product. PVA needs contact; it is not a gap filler.
- Longer clamping times may be required for joints under high stress.
Clean up and handy tips
Uncured adhesive comes off with water. Cured adhesive has to be sanded or scraped. Shake the bottle before use. To fill small gaps, Aquadhere can be mixed with sawdust — useful for tidying a dowel plug that sits a little loose.
Common questions about building a drinks trolley
What size should I make it?
900 mm high and 1600 mm long is the size used here, but any size that suits your space works. Set the internal width to match your sink or esky.
Why glue the joints if I am screwing them?
The screws hold the joint together; the glue spreads the load along the whole face and stops the frame racking. Aquadhere Exterior produces bonds stronger than most woods.
Do I need to clamp it?
The batten screws clamp the joints. Where you do clamp, allow 30 minutes for softwoods and 1 hour for hardwoods.
When can I load the cart up?
Do not stress the joints for 24 hours. Maximum strength is attained in 24 hours, longer in cold, damp conditions or with dense timbers.
Should I glue both surfaces?
No. Apply the adhesive liberally to one surface only.
How do I clean off the squeeze-out?
Wipe it with a damp cloth while it is still wet. Anything you miss can be sanded once dry — and it must be, because cured glue on the surface will not take varnish or stain evenly.
Can I use my indoor wood glue instead?
No. Aquadhere Interior is interior-only and not waterproof. For anything living outdoors, use Aquadhere Exterior.
Why is my glue line staining dark?
Aquadhere stains brown or black if contaminated with rust, or in the presence of tannins in many woods. Keep steel and iron out of the glue and off wet joints.
Can I paint or varnish over the glue?
Sand any cured squeeze-out back first. Aquadhere Exterior dries clear with a yellow tinge, and a residue on the surface will show through a clear finish.
How much glue do I need?
Coverage is approximately 5 m² per litre. A 250 mL or 500 mL bottle covers a cart of this size comfortably.
Can I leave the cart out in the rain?
It is a weatherproof glue and an exterior varnish, but the trolley is still timber. Keep it out of continuous water and re-coat the finish when it starts to look tired.
What if my dowel plugs are loose?
Mix a little Aquadhere with sawdust to fill the gap — that is a documented tip on the data sheet — then sand flush once dry.
What size should I make it?
900 mm high and 1600 mm long is the size used here, but any size that suits your space works. Set the internal width to match your sink or esky.
Why glue the joints if I am screwing them?
The screws hold the joint together; the glue spreads the load along the whole face and stops the frame racking. Aquadhere Exterior produces bonds stronger than most woods.
Do I need to clamp it?
The batten screws clamp the joints. Where you do clamp, allow 30 minutes for softwoods and 1 hour for hardwoods.
When can I load the cart up?
Do not stress the joints for 24 hours. Maximum strength is attained in 24 hours, longer in cold, damp conditions or with dense timbers.
Should I glue both surfaces?
No. Apply the adhesive liberally to one surface only.
How do I clean off the squeeze-out?
Wipe it with a damp cloth while it is still wet. Anything you miss can be sanded once dry — and it must be, because cured glue on the surface will not take varnish or stain evenly.
Can I use my indoor wood glue instead?
No. Aquadhere Interior is interior-only and not waterproof. For anything living outdoors, use Aquadhere Exterior.
Why is my glue line staining dark?
Aquadhere stains brown or black if contaminated with rust, or in the presence of tannins in many woods. Keep steel and iron out of the glue and off wet joints.
Can I paint or varnish over the glue?
Sand any cured squeeze-out back first. Aquadhere Exterior dries clear with a yellow tinge, and a residue on the surface will show through a clear finish.
How much glue do I need?
Coverage is approximately 5 m² per litre. A 250 mL or 500 mL bottle covers a cart of this size comfortably.
Can I leave the cart out in the rain?
It is a weatherproof glue and an exterior varnish, but the trolley is still timber. Keep it out of continuous water and re-coat the finish when it starts to look tired.
What if my dowel plugs are loose?
Mix a little Aquadhere with sawdust to fill the gap — that is a documented tip on the data sheet — then sand flush once dry.