Scavenger Chic

Metal File Box becomes a Bar Cart

• By Joan
• December 5, 2016
• 4 Comments

It’s back to the flea market again today.  This time with a fun upcycle of the metal green file box. Can you see a bar cart?

The metal green file box I found at the flea market wasn’t much too look at, but I knew I could incorporate it into another project where I needed a drawer.

Over the last few months my mind has flip flopped all over the place over where I should insert my new drawer; I even thought about inserting it into the hand cart coffee table, but I finally settled on a kitchen or bar cart.

I did need more supplies than those shown above, but this is what I started with…some pallet wood, one inch scrap plywood, the metal file box,  one, 6′  1×2 , one 8′ 2×2  and 2 6′, 2×2’s.

From the 2×2’s, cut four 29″ legs.

I used 2×4’s for a butcher block top.  If you do not want your top as thick as mine, you may need to make your legs longer.

Since I am working around my file box, all my measurements were made based on the height and width of the box.

I cut four 1×2’s  (13 1/2″), the width of the box minus the 2 leg widths plus 1/4″. The 1/4″ is just for a little wiggle room.

The scrap plywood was cut (you need 2 of these). For the height, measure the height of the file box plus the width of 2- 2×2’s.  For the length, measure the length of the 1×2’s you cut in the last step.  

If that didn’t make sense, hopefully the picture above will give you a better sense.

Use wood glue and nails (or screws) to attach the 1×2’s to the plywood.  Do all your nailing and screwing from the plywood side of the wood to hide the nail/screw holes.

Cut 2 more pieces of the 2×2’s the same length as the 1×2’s.

Use either long screws or  Kreg jig pocket holes and wood glue to attach all your pieces as shown. 

Back to the file box…measure the width of the drawers (add another 1/4″ for wiggle room) and use this measurement to cut 5 more lengths of the 2×2’s.

With more wood glue and either pocket holes or long screws, attach 4 of the 2×2’s as shown – three in the back and one at the top in the front.

I had some scrap bead board I used for backing for a storage cupboard, but feel free to use whatever you have…I’m thinking pallet wood!

Back to the front, make sure the file box still fits…Yay!!

With 1×2’s I glued and nailed on a ledge for the file box to sit.

Attach the last 2×2 just below the file box. 

You can see some of the pocket holes in this picture.

I wanted a really thick butcher block top but I didn’t particularly like the cost of premade, so I decided to make my own out of 2×4’s.  Using 4, 2x4x8′ cut into 12- 30 inch pieces, I glued and screwed until I had a nice fat butcher block top.

I’m not sure I would do this type of butcher block again because each of the 2×4’s had a nice rounded edge which makes for a very grooved top.  Forty five minutes of sanding later and I was still trying to flatten those grooves. 

Cut pallet wood to fit for a bottom shelf, nailing the pieces onto the existing 2×2’s.

Ignore the white paint…I changed my mind.  

 

I attached casters to the legs for easy maneuvering.

This cart rolls around pretty easily. If you’d like it not quite as roly poly, there are casters that lock into place.

Before attaching the top, drawers and shelf permanently, the cart got a coat of red chalk paint.

More scrap wood was screwed into the sides at the top of the cart.

Turning the cart over, ten more screws thru the pieces I just installed attaches the butcher block to the cart.

The butcher block was finished with a frame of a pallet wood, black chalk paint and vintage wax.

The file box was reinserted and attached permanently with builders adhesive, so it doesn’t keep pulling out every time I open the drawers.

The insides of the drawers still looked a little ‘file boxy’…

…so they were finished with another piece of the beadboard, cut to fit inside the drawer.

The side pieces were created from pallet wood side rail pieces screwed into the 2×2’s.  The towel rack is a piece of copper pipe and the front of the book holder is even more pallet wood.

All dressed up and waiting for a party.

I’m still adding to my flea market flips. This bar cart makes project number 7  from the flea market.  If you like, you can check out my other flea market flips here…Hand Truck Coffee Table,  Apple Picking Bucket ,  Feed Sack Ottoman, Barrel Hoop Mirror,   Thingamajigs and Pendant Light. I think I’m running out of room on my picture. 🙂

Have a wonderful week and stay inspired.

Shared at Metamorphosis Monday, Wow us Wednesdays,

DIY Salvaged Junk Projects, Handmade Hangout Party,