Have a professional install any needed utility lines before you install your base cabinets. Try to come up with a design for the layout, then have them install connections to fit your configuration.
The most affordable configuration is a simple line setup, which would sit against your home or extend out as a peninsula. It would consist of a grill flanked by bases with cabinetry and countertops. You could also designate spots for a sink and mini-refrigerator, but space might get tight. L-shaped configurations are more elaborate and more expensive. The grill, flanked by cabinet bases, could sit against your home. More bases with cutouts for a mini-fridge, sink, and storage could extend out as a peninsula to form an L-shape. If you have more space available, you could extend another peninsula on the other side to form a U-shape. Keep in mind a more elaborate setup will require more building materials and, if you’re hiring someone, higher labor costs.
If you’re building your own bases, the easiest DIY method is to use treated plywood to construct a frame, then cover it with a brick or stone veneer. Since wood is combustible, you’ll need to install an insulated grill tray (if your grill will be built-in) and cover the frame with wire lathe before adding mortar and the veneer. If you’re having a contractor build your bases, they’ll use a steel or concrete frame to support the veneer.
In addition, your layout will depend on which appliances you need. For instance, work a gap between 2 cabinet bases into your design to match the size of a mini-fridge. If you know your fridge’s dimensions from the start, you can make your cabinets the same height so the countertop will fit seamlessly over the cabinets and fridge. Make sure your appliances are rated for exterior use.
Once they’re delivered, you can arrange and connect the bases using metal fasteners and construction adhesive. You can purchase bases with openings for gas, water, and electrical lines, then have a professional plumb or wire them.
Use a circular saw to cut your plywood boards to the right sizes. You’ll want your bases’ total height to be about 38 inches (97 cm), but you’ll need to factor in your the height of your countertop when you cut your plywood posts. Subtract your countertop height from 38 inches (97 cm) to find the right height for your corner posts. To create cube-shaped modules, make your horizontal boards the same size as your corner posts. You could make multiple modules, place on on each side of your standing grill, and add others to create a peninsula.
An insulated jacket is needed to contain the heat produced by the grill. If you already have a standing grill, you can just build your cabinet modules and place them around your grill.
Glue and screw on the plywood panels onto the other 3 faces of the box, leaving the top and bottom open.
Remember to include cutouts for cabinets in the felt to match those cut into the plywood panels.
Wear gloves when working with wire lath. Remember to include cutouts for the cabinets in the lath.
Create a cabinet box for each cutout you’ve made in your modules. Set the boxes aside until you’ve laid a scratch coat of mortar. You can’t just repurpose old interior cabinets without building a veneered base around them. They won’t hold up to the elements.
Before you start working, lay a border of scrap boards around the base to catch excess mortar.
These scores will help hold the veneer to the surface.
Don’t cover the flanges, or lips, of the cabinet boxes with veneer. Leave the flanges exposed so you can screw your door hinges onto them. Allow the veneer to set for 24 hours.
If you have to go with wooden doors, seal them with a wood varnish labeled for exterior wooden furniture. After 2 or 3 years, you’ll probably have to sand the doors and freshen the varnish. [18] X Research source
If there’s a problem with the fit, have the stone delivery person or manufacturer make adjustments with a diamond-tipped saw.
If you have a standing grill, slide it into place between your base modules. If you’ve included a mini-fridge in your design, plug it in and slide it into its designated space.
