GuideOutdoor Kitchens & BBQ
Outdoor Kitchens & BBQ · Guide
Build an Outdoor Grill Prep Station and Side Table
Grilling is much easier with a proper place to set down plates, cut meat and keep tongs, sauces and fuel within reach. This freestanding prep station stands beside the grill, not against it, and is built like a sturdy outdoor workbench.
What you will build
The station has four legs, a top at counter height and a lower shelf. The top can be solid boards sealed with a food-safe finish, or slats with a removable cutting board on top. Hooks on the side rail hold tools and towels.
The most important rule is distance from the heat. Wood and grills do not mix at close range: follow your grill manufacturer's instructions for the minimum clearance to combustible materials, and keep the station at least that far away, on the side away from where heat and smoke drift.
Real-world examples
Photos of similar builds by other people, shared under open licenses. They show the idea in practice; the details differ from this guide.
Materials
- 4 legs 2 × 4 in (45 × 95 mm), about 34 in (86 cm) long
- 2 × 4 in lumber for the frame rails, about 24 ft (7.3 m)
- Boards about 1 × 6 in (20 × 145 mm) or decking for the top and shelf
- Exterior screws 1½ and 2½ in (40 and 63 mm)
- Hooks and a towel rail
- Optional: a large food-safe cutting board
- Exterior finish for the frame, food-safe oil for the work surface
- Optional: two lockable castors
Tools
- Tape measure and square
- Mitre saw or circular saw
- Drill/driver
- Clamps
- Spirit level
- Sander
- Safety glasses
Step by step
1Plan the placement first
Look up the clearance to combustible materials in your grill's manual and measure where the station will stand. Choose a level spot beside the grill, away from the direction smoke usually blows, and not under overhanging branches or a roof.
2Build the end frames
For each end, join two legs with a rail at the top and another about 8 in (20 cm) above the ground. Screw through pilot holes, two screws per joint, and check that the frames are square.
3Join the frame
Stand the end frames up and connect them with long rails front and back at both levels. Check the top rails are level; a level top stops bottles and bowls sliding.
4Fit the top
Screw boards across the top frame, either tight together for a solid surface or with small gaps for drainage. Let the top overhang the frame slightly at the front so you can work close to it.
5Add the shelf and hooks
Lay boards on the lower rails to make a shelf for charcoal, plates and covers. Fit hooks or a rail on the side away from the grill for tools and towels.
6Finish and protect
Sand everything smooth. Use an exterior finish on the frame and a food-safe oil on any surface food will touch, or keep a separate cutting board for food. Add lockable castors if you want to wheel it away after use.
Tips for a better result
- Store charcoal and lighter fluid on the shelf only when the grill is cold, and in a closed container.
- A hook for a small fire extinguisher or fire blanket nearby is worth having.
- Cover the station when not in use to protect the top from rain and leaves.
- Keep raw and cooked food apart with two boards or two zones on the top.
Common mistakes to avoid
- Pushing the prep table right up against the grill.
- Using paint or varnish on a surface you cut food on directly.
- Placing the station downwind, where smoke fills your work area.
- Building it on an uneven surface without levelling, so it rocks.
Safety
- Follow your grill manufacturer's clearance to combustible materials, and never use the grill under a roof or in an enclosed space.
- Keep a fire extinguisher or fire blanket within reach, and let ashes cool completely before disposal.
- Keep children and pets away from the grill area while it is in use.
- Wear safety glasses when cutting and drilling.
General guidance only. Follow the instructions for your tools and materials and your local rules, and use a qualified professional for electrical, gas and structural work.
Finishing up
With a solid prep table beside it, the grill becomes an outdoor kitchen. Wipe the top after every use, re-oil the food surface now and then and keep the station covered, and it will serve many summers of cooking outdoors.
About this guide: written by the DIY Outdoor Builds editors from general, widely used building and gardening practice. Text and illustration © DIY Outdoor Builds. Photos are by the people credited under each one, used under their licenses. Found an error? Let us know.
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