Rustic Coffee Cart

This project was built in stages and evolved organically as I worked through the structure and finishes. All components are organised into separate canvases in the xTool Studio (.xcs) file, with materials labelled. The steps below reflect the order in which I made them, but I'm sure they are flexible. 

The build begins with the box base, which forms the foundation of the cart.
I used 6mm MDF as my main material, and assembled this first to establish the overall footprint, height and proportions of the cart. The box is designed to be open at the back so power boards and cables can be hidden within the cart.

The first inner cart layer sits around the base and helps define the internal structure and shelf layout. It also supports the main strut. I wanted to create a bed at this point to fill with coffee beans and resin.

The second inner cart layer adds depth and rigidity and supports the smaller outer strut.

Minor adjustments can be made here to suit different materials or thicknesses.

The outer cart panels wrap around the structure and are responsible for most of the cart’s visual identity. For this, I used wooden craft sticks, disressed them with sandpaper and steel wool, then stained them. I glued them onto 2mm ply before cutting out the panels (6mm MFD for the top parts, but makes no difference).

This is another area where you can have some fun with the finish.

The outer cart bar is added to complete the front profile of the cart and visually ties the outer panels together. It sits above the outer cart panels and should be a different material / thickness to the section below. I used 6mm material that sat out a little further than the cart panels below. I ultimately covered them in hessian.

With the cart body complete, the build moves upward to the canopy frame.

This frame establishes the height and proportions of the upper section and supports the canopy details. Think of it as a rib cage - the support bars sit inside the frame and act as the spine.

The canopy cover is added last to complete the top structure.

This is another great opportunity to experiment with materials and introduce softer, tactile elements. I used 3mm ply and stained every second panel. Carefully place them over the frame, clamping as you go to maintain the shape. Then glue the cover stips over the seams. Careful with this bit as it's very fragile - I ended up snapping one and having to recut it.

The canopy struts connect the frame to the cart body and add both strength and a great industrial element. They slot into the inner cart layers. You can also add the inner and outer struts here as well. The short piece is the inner strut (which should rest flush on the base), while the longer piece is the outer strut and that slides into the second inner cart layer. Now glue the canopy and frame onto each strut.

Ok, so this is the part where I strayed off track and decided to have a little fun. All the finishes I mention here are obviously optional and a personal choice. To finish the cart top, I set real coffee beans in resin to create a durable, textured surface.

I sealed the surface first, then poured the resin in layers, allowing 24 hours between pours. You will see from the close up photos that there are a few air bubbles in the resin, however I didn't mind the imperfections. Let your creativity go wild here.

The finishing stage is where this project really came to life.

I experimented with materials including hessian, twine, plaster, paddle-pop sticks and layered textures to give the cart a more lived-in feel. I also added lights into the canopy. I then aged it by scouring it with steel wool and sandpaper, and firing it with a blow torch before sealing the whole piece. This also helped to burn off the freyed edges of the twine and hessian. 

This stage is intentionally flexible.

All engraving, signage and coaster designs are grouped together on a separate canvas. Note that the little “coffee” plaque at the bottom is just from a mold I had and I engraved it. Same thing with the coasters - they are made out of plaster, with painted ply insert which I engraved, then set in resin for durability and to withstand the heat from the mug.

The mugs themselves are just cheap mugs froms Kmart which I painted with cold galvanizing compound and engraved using the rotary attachment.

The lights are also just cheap strip and mini LED spotlights from Temu - maybe a couple of dollars each. I ran the cables down both struts and wrapped them in twine. Power for this sits underneath the cart with full, open access at the back. There is enough room for a six-way powerboard, so I plug my kettle and milk frother in there as well.

These elements personalise the cart and can be customised with names, quotes or symbols.

Once everything is assembled, finished and in place, the final step is the most important one: make yourself a cup of coffee.

As I said, we don’t have a fancy machine in our house - just instant coffee - but that doesn’t stop it from being an important daily ritual. Every coffee is made with love, and it honestly inspires my creativity when I need it the most - as the day is starting.

Take a moment, enjoy the space you’ve made, and start the day properly. Happy creating!!