GRAINBENCH ORIGINALS
The Everyday Serving Tray
A simple tray with a plywood base, low sides and two cabinet-pull handles.
20 in W × 14 in D × approximately 3 in H
Printable drawings, a labelled cut list and nine assembly stages. No account or email required.
Common materials. Clear details.
One 1x3 board, a plywood base and two cabinet pulls.
Use straight, dry stock and check its actual thickness. The PDF lists quantities, hardware sizes, part labels and the cutting layout.
Shopping list
- 1x3 x 8 ft: 1 board; actual 3/4 x 2-1/2 in.
- 1/2 in plywood: One flat piece at least 20 x 14 in; a 2 x 2 ft project panel is sufficient. Measure actual thickness.
- Frame screws: 8 x #8 x 1-1/4 in coarse-thread pocket screws for softwood, plus spares.
- Base screws: 12 x #6 x 1 in flathead wood screws, plus spares.
- Handles (H): 2 cabinet pulls with 4 in hole centres, with their matching machine screws for a 3/4 in drawer front. Buy before drilling; do not mix thread types.
- Other supplies: Interior wood glue, sandpaper and a suitable wipeable interior finish.
Before the first cut
Tape, square, pencil, supported crosscut saw, drill/driver, clamps, sander, and suitable eye/hearing/dust protection. Pocket-hole jig and bits, countersink, a saw/guide for the plywood, and the handle maker's recommended clearance drill bit.
Digitally checked; not physically built or load-tested. Follow the PDF’s fixing, stability and inspection instructions.
Your parts at a glance
Dimensions in inches. Stock names are nominal; finished dimensions are actual.
| ID | Part | Qty | Stock | Length | Width | Thickness |
|---|---|---|---|---|---|---|
| A | Long rails | 2 | 1x3 | 20 | 2-1/2 | 3/4 |
| E | End rails | 2 | 1x3 | 12-1/2 | 2-1/2 | 3/4 |
| B | Overlay base | 1 | 1/2 ply | 20 | 14 | 1/2 nom. |
A clear way through
Keep the PDF beside you for the dimensioned drawings and drilling layouts.
01 Cut long rails (A), end rails (E) and base (B)
Cut the rails square. Cut B to 20 x 14 in with a supported saw/guide and check its diagonals match. A and E stand on B; E fits between the two A pieces. Mark inside faces and bottom edges.
02 Mark end rail (E) and handle (H) locations
For each E, mark its horizontal midpoint at 6-1/4 in and its vertical midpoint at 1-1/4 in above the lower rail edge. A true 4 in centre-to-centre pull places holes at 4-1/4 and 8-1/4 in along E. Confirm these marks against the ACTUAL pull before drilling.
03 Dry-fit rails (A/E) over base (B)
The rail frame outside size must be 20 x 14 in and the inside opening 18-1/2 x 12-1/2 in. Keep rail lower edges flat and coplanar; no glue is applied until the frame fits the base without forcing.
04 Drill pockets in end rails (E)
Use #8 x 1-1/4 in coarse-thread pocket screws for the specified softwood, with a head approved for the jig. Set jig and stop collar for the actual 3/4 in stock. Test on matching offcuts, clamp square and drive at low clutch torque; check for splitting, stripping and projecting tips. Put two pockets at each E end on its INSIDE face, centred 5/8 and 1-7/8 in above its lower edge. There are eight frame screws total. Drill the handle clearance holes from the confirmed template, backing the exit face with scrap to avoid tear-out.
05 Join long rails (A) and end rails (E)
Glue the E ends lightly, clamp E between A with all lower edges flush, then drive two pocket screws at each corner. Keep pocket holes inside the tray. Check matching frame diagonals before the glue cures.
06 Glue and screw base (B) under rails (A/E)
Mark the rail centre lines on B underside. Along each long rail use four base screws at 1-1/2, 7-1/8, 12-7/8 and 18-1/2 in from one end. Along each end rail use two at 3-1/2 and 10-1/2 in measured across the 14 in base depth. Drill clearance holes through B, pilot the rail edges, and countersink lightly. Glue, clamp and drive twelve #6 x 1 in screws upward into the rails; do not overdrive through the plywood.
07 Finish rails (A/E) and base (B)
Ease exposed edges lightly by hand, leaving joining faces square. Sand with 120 then 180 grit as appropriate and remove dust. Test the finish on an offcut. Follow its preparation, ventilation, application and full cure directions. Smooth the underside and make all base screw heads flush so they cannot scratch a table. Follow the finish maker's full cure directions before use. Serve dishes on the tray rather than unwrapped food directly on the wood.
08 Fit handles (H) to end rails (E)
Fit the matching machine screws from the tray interior into each external pull. Screws must clamp the 3/4 in rail without bottoming in the handle; use the pull maker's screw length and thread. Do not substitute longer screws blindly. Tighten evenly by hand and confirm there are no projecting tips or sharp heads.
09 Inspect handles (H), rails (A/E) and base (B)
Check every corner, the base bond and all fasteners. With the tray near a padded surface, test the empty tray by both handles, then with a small light load. Stop if anything moves, cracks or loosens. Correct defects before carrying items; keep loads balanced and do not carry hot liquids during an initial test.
A little help along the way
You may sell your finished makes. Please keep the plan files and images with GrainBench. Plan usage terms → · Questions or corrections?
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