How To Make A DIY Breakfast Tray | Video

Great for sick days, the weekend, and spoiling your favorite people, breakfast trays are a classic item to have around the house. Building one is a fun, easy project you can do in an afternoon. Here’s what you’ll need for…

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TOOLS & MATERIALS

Miter Saw
Power Drill
3/8″ Drill Bit
Phillips Bit
Pencil
Tape Measure
2 – 36″ Clamps
Combination Square
Scissors
1″ x 2″ x 96″ Pine Board
1″ x 4″ x 96″ Maple Board
1-¼” Self-Tapping Wood Screws
Mineral Oil
12″ x 24″ Sheet Steel
Rag
All-Purpose Adhesive
36″ of Paracord Rope
Nitrile Gloves (optional)

When taking on this DIY task be sure to equip yourself with the proper safety gear.

SAFETY GEAR

Eye Protection
Ear Protection
Mask

STEP ONE

Measure and cut wood. Using a power or hand miter saw to make the following cuts. From one-by-two pine: cut four 10‑½” pieces (middle support). Cut to two 23-7/8″ pieces (long support). From one-by-four maple, cut two 13‑½” pieces (sides). Cut two 24″ pieces, long sides.

STEP TWO

Assemble wood sub-frame. Make two marks on top of your 23-7/8″ pine pieces, one at 8″ and one at 16″. These will indicate where your two middle supports will be placed. Apply wood glue to the ends of all four 10-½” pieces, then place them inside the longer pieces as shown. Clamp and fasten with self-tapping screws through the long supports and into the middle supports.

STEP THREE

Assemble maple sides. Apply glue to one long side of your sub-frame and clamp it flush alongside the bottom of one 24″ maple piece. Clamp to your work surface and secure with 1‑¼” screws. Flip, and repeat on the other side. Apply glue to the short ends, and clamp the 13‑½” pieces in place. Fasten the side pieces with screws, and remove clamps.

STEP FOUR

Drill rope holes. Using a combination square, mark 4-½” from the edge of the short ends of your 13‑½” piece, then mark four rope holes ¾” from the base of your tray at your previous marks. After you’ve made your marks, drill through both pieces at all four locations with a 3/8″ bit.

STEP FIVE

Sand. Sand your entire tray with 150 grit sandpaper, rounding edges as you see fit. Repeat with 220 grit sandpaper until you’re happy with the finish. When you’re done, wipe with a tack cloth or a rag.

STEP SIX

Attach handles and metal surface. Cut two pieces of rope 12″ to 18″ long. Tie knots securing the handles in place and apply a small amount of glue on each knot seam. Apply a bead of all-purpose adhesive on the interior frame and set your sheet metal in place. Let dry per manufacturer’s instructions.

STEP SEVEN

Finish your tray. Generously apply mineral oil to the surface with a rag, reapplying until you achieve the look you’d like.

Your build is complete.

Looking for great tools to help get your project done? Shop Stanley, Black & Decker and DeWALT for everything you need!