Prepare the Tray Sides & Supports
Cut the two tray sides (A) and three slat supports (B) to the same length (Deck Tray Project Diagram, Drawing 1). Then cut the two bracket supports (C) to length (3/4 inch shorter than the slat supports and tray sides). Sand the parts smooth and wipe clean.
Tip: Cutting like parts to the same length is crucial to this project, but that's easy when using a miter saw or table saw. Place a built-in or clamp-on stop at a distance from the saw blade that's equal to the part length to be cut.
Cut a Spacer
Find or cut a piece of 3/4 in.-thick stock about 4 in. long for use as a spacer. Glue and clamp a tray side (A) to a slat support (B) with the ends flush and a 1 3/4 in. gap between the top of the slat support and the top of the bracket support. (The spacer provides the correct offset without measuring.)
Repeat for the other side and slat support.
Attach the Slat & Bracket Supports
Glue and clamp a bracket support (C) centered on a slat support (B) with the face of the bracket support flush with the edge of the slat support. (There should be 3/8 in. gaps between the ends of the bracket support and ends of the slat support.) Repeat for the other slat support and bracket support to complete the second side assembly.
Make the Front & Back
Cut the tray front and back (D) to length, sand smooth, and wipe clean. Glue and clamp the front and back to the two side assemblies (ABC) with the top edges flush.
Prepare the Slats
Measure between the sides and cut the three bottom slats (E) to length (Deck Tray Project Diagram, Drawing 2). Sand the top faces smooth and wipe clean. Glue and clamp one outside slat to the tray with the slat edge even with the ends of the bracket supports. (The tray is shown upside down here.) Repeat for the opposite side, leaving a space in the center.
Attach the Middle Slat
Glue and clamp the middle slat centred between the outside slats.
Attach the Third Slat Support
Glue and clamp the third slat support (B) centred between the end supports. (Shown here upside down with clamps removed for clarity.)
Sand the tray smooth and wipe clean. Then apply two coats of exterior paint. Allow the paint to dry overnight.
Make the Tray Hangable
To hang the tray from a deck rail, adjust the brackets so that the front vertical piece slides up between the tray front and the outside slat. Then fit the top half of the brackets to your deck rail. Space the brackets so they're about 13 1/2 in. apart, and slide the tray down onto the brackets. The tray bracket supports should rest on the metal brackets.
How To Terms
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