The Ultimate Kitchen Storage Trolley Build In 5 Steps

Aluminium flat bar positioned along the edges contrasts with the plywood and disguises the joins. Cut the aluminium using a mitre saw with a metal cutting blade, or use a timber cutting blade lubricated with a spray of WD-40.

Apply two coats of Zinsser Bulls Eye Clear Shellac using a fine natural brush.

Shellac dries quickly, so try to avoid drips or blotches as there’s no time to wipe up errors.

Finish with a protective layer of beeswax furniture polish.

White and yellow woodworking adhesives are water-based polyvinyl acetate glues, or PVAs.

Yellow glue has a shorter drying time than white, usually up to 10 minutes, and keeps its colour when dry, while white PVA dries clear.

Cross-linking PVAs have greater inherent holding powers, as the strands interlock when bonding, improving the strength of the join.

For a project like this kitchen trolley, where a mixture of strength and speed is required, use a yellow cross-linking PVA such as Titebond Premium II, $15 for 473ml, from Titebond. www.titebond.com.au

Nine boxes form the frame of the unit, which is reinforced with an outer layer of plywood. Let’s get started!

To make the base, mid and top boxes, position the sides of each box between a top and base, securing with yellow PVA adhesive and 15mm brads, then position and secure the matching box back.

Begin assembly by joining the centre column, stacking a base, mid and top box, applying adhesive between each, clamping and securing with five brads at each joint.

TIP: Angle the gun slightly to avoid driving the brads all the way through

Position the top and base layers, securing with adhesive and brads, clamping until dry.

Secure the side and back layers then secure the top back and side inner layers of the shelf.

TIP: Drive brads from inside into the outer layers

Cover the brad heads in coloured timber putty and use a belt sander along the joins to make the edges flush.

Attach two trunk handles on each side and four 75mm castors underneath, using lockable castors at the front.

Position the trim along the edges, applying a thin layer of construction adhesive to each, starting with side verticals, then front horizontals and centre verticals, mitring the corners of the top edge then adding the rear edge angle.

Hold with tape until dry.

Create an industrial finish by adding metal components.

• Add heavy-duty 75mm castors, two swivel, about $25 each, and two lockable, about $27 each, to keep the trolley in place when it’s loaded up with breakables.
• Add pairs of galvanised trunk handles to each side to control trolley movement.
• Add aluminium flat bar to cover all joined edges and aluminium angle to cover the rear vertical edges.