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 this inexpensive project:
TOOLS & MATERIALS
- Miter Saw
- Power Drill
- 3/8″ Drill Bit
- Phillips Bit
- Tape Measure
- 2 – 36″ Clamps
- Combination Square
- 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
- 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.
- Eye Protection
- Ear Protection
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.
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.
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.
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.
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.
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.
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.