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6 Foot Home Bar

Home Bar Plans - Assembly Instructions Parts Drawings & Dimensions available from www.BobsPlans.com Entertain your friends in style with this beautiful oak bar. The top is 6 ft. long and 24 deep. The overall height about 42. The classic design features solid oak armrest molding, solid brass foot rail, a convenient work shelf in the rear, three drawers, and two sliding wine racks. The cabinet is made of oak veneered plywood. The trim and drawer fronts, from solid oak. The extensive use of pocket holes makes the assembly of this project easy and intuitive. If you have never used pocket holes in your woodworking projects, youll wonder how you ever got by without them. Pocket hole joints are extremely strong and there is no measuring. You simply drill the pocket holes in one of the work pieces to be joined, (the exact location is not critical), clamp the pieces together and insert the screws. Since the screws remain in the joint, they serve as both a dowel and a permanent clamp.

Copyright 2005 by Robert E. Reedy All rights reserved

Table of Contents

Part 1 - Assembly Instructions

Attach Drawer Slides ..................................................................... 1 Attach Wine Rack Slides - Assemble Bottom ............................. 2 Attach Vertical Dividers & Kick Panel ........................................ 3 Attach Side Panels and Work Shelf ............................................... 4 Assemble Front & Side Panels ...................................................... 5 Attach Front and Side Trim ........................................................... 6 Install Upper Horizontal Trim ....................................................... 7 Arrangement of Rear Trim ............................................................ 8 Install Brackets & Measure Side Rail Length ............................... 9 Measure Front Rail Length - Assemble Rails .............................. 10 Assemble Armrest Molding ......................................................... 11 Drill Pocket Holes in the Top ...................................................... 12 Attach Rear Trim to the Top ........................................................ 13 Attach Risers to the Top .............................................................. 14 Attach Top to Molding & End Soffit ........................................... 15 Attach Center Soffit ..................................................................... 16 Assemble Drawers ....................................................................... 17 Assemble Wine Racks ................................................................. 18 Cutout Suggestions (1)..................................................................19 Cutout Suggestions (2)..................................................................20 Cutout Suggestions (3)..................................................................21 Additional Plans & Pocket Hole Jig Links ...................................22

Pros Choices - Woodworking Tools & Accessories

Note: Images and underlined blue text are active web links.

Kreg K3 Pocket Hole Jig Large Plate Router Table

Saw Blade Tool

Incra Miter Sled

Leigh Dovetail Jig

Avenger Dado Set

Incra Miter Guage

Drill Doctor

Clamping Miter Gauge

Clamp Clip

Brad Nailer

Rotary Shaper

Tenon Cutters

Self Centering Bits

Roller Stand

Tormek Sharpening

Copyright 2005 by Robert E. Reedy, Vandalia, Ohio All Rights Reserved

Pros Choices - Woodworking Jigs & Accessories

Note: Images and underlined blue text are active web links.

Taper Jig

Rip Fence

Dovetail Jig

Kreg 2000 Pocket Hole Jig Heavy Duty Tenon Jig

Router Mortise & Tenon Jig

Miter Mate

Incra Miter Gauge

Fingerjoint Jig

Pipe Clamps

Carriage Tenon Jig

Miter Slot Bar

T-Track & Hardware

Hold Down Clamp Kit

T-Slot Cutter

Toggle Clamps

Copyright 2005 by Robert E. Reedy, Vandalia, Ohio All Rights Reserved

Materials You Will Need

Two Sheets of Oak Veneer Plywood - See Cutout Suggestions (1) One Sheet of Oak Veneer Plywood - See Cutout Suggestions (2) One fourth Sheet of Hardboard - See Cutout Suggestions (2) Four 5 by 8 by Oak Boards One 6 by 8 by Oak Board 10 Ft. of Oak Armrest Molding - Rockler Item # 42768 & 42777 Link: http://www.rockler.com/findit.cfm?page=5762&sid=AF913 10 Ft. Brass Foot Rail Kit - Rockler Item # 57684 Link: http://www.rockler.com/findit.cfm?page=907&sid=AF913 Five Sets of 14 Drawer Slides (May be at local hardware stores) Rockler Item # 34835 Link: http://www.rockler.com/ecom7/product_details.cfm?offerings_id=1507&sid=AF913 Three Drawer Pulls (Available at Rockler or local hardware stores) Pocket Hole Face Frame Screws (One or two pounds) 1 Flathead screws (About 50) 1 Finishing Nails (Less than a pound) 1 Finishing Nails (Less than a pound) 7 Small Angle Brackets (Available at local hardware stores)

Tools You Will Need

Table Saw Drill Pocket Hole Jig Sander Hand Tools

Pockets holes are about the easiest way I know to join wood. You simply use the jig to drill a pocket hole in one work piece, apply some glue, secure the pieces with a clamp, then insert the screw as shown in the Illustration. If you have not experienced the ease and efficiency of pocket hole joinery yet, maybe youll be ready to try it after looking through these assembly drawings and instructions. You can get a simple pocket hole jig kit with a step drill and stop collar for less than $20 and a really nice one for less than $150. Note: A drill press pocket hole jig isnt suitable for the plywood panels required for this project. A selection of suitable pocket hole jigs are pictured on the last page of this document.

Attach Drawer Slides

Page 1

If you will be adding drawers to your bar, attach the drawer slides to cleats as shown. Three must have the roller on the right and three must have the roller on the left. The lowest part of the drawer slide must be flush with the bottom of the cleat. The roller section must protrude past the end of the cleats by 3/4" (the thickness of the trim).

Lowest part of drawer slide is flush with bottom of wood

17" 22 3/4" 16 1/4" 5 3/4" 10 1/2"

Attach three cleats with drawer slides to the left side as shown above. Attach two cleats with drawer slides to left divider panel as shown above. Note: The bottom cleat and drawer slide for the left divider is attached to the bottom with pocket holes later. It will then provide a way to attach the left divider to the bottom.
Copyright
C

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Wine Rack Slides - Assemble Bottom

Page 2

If you will be including wine racks, in your bar, attach the drawer slides to the divider panels as shown. Note: the drawer slides for the wine racks do NOT protrude 3/4" past the edge of the divider panels. This is because the wine rack fronts will be flush with the opening while the drawer fronts will be on the outside of the opening.

14 3/4" 9"

Attach the cleats to the top surface of the bottom plate as shown. Pocket holes sides should be placed 16" from the ends with pocket hole sides facing each other as shown. (These cleats are used for mounting the vertical panels to the bottom surface.)

Attach two cleats to the ends of the bottom surface with pocket hole screws. These cleats are flush to the edges of the bottom.
Copyright 2005 by Robert E. Reedy, Vandalia, Ohio

Attach Vertical Dividers & Kick Panel

Page 3

Attach the vertical dividers to the cleats as shown. Attach the front cleat between the panels as shown with pocket hole screws.

Front cleat Screws on this side.

Turn the assembly upside down and attach the kick panel as shown with pocket hole screws. Note: the pocket hole screws are on the back side of kick panel.

Copyright

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Side Panels and Work Shelf

Page 4

Attach the small shelf to the cleats with finishing nails.

Now, attach the four cleats to the bottom side of the work shelf with pocket hole screws as shown. The end cleats have pocket holes facing out. The middle cleats have the pocket holes facing each other. The pocket hole side of the middle cleats are placed 16" from the ends of the workshelf.

Attach the side panels to the bottom cleats with 1 1/4" screws.

Place the work shelf (with cleats attached) on top of the vertical dividers and secure it to the sides and dividers with 1 1/4" screws through the cleats. Attach the upper front cleat between the dividers with pocket hole screws.
Copyright
C

2005 by Robert E. Reedy, Vandalia, Ohio

Assemble Front & Side Panels

Page 5

Assemble the three front pieces as shown and secure with pocket hole screws. These screws will be covered with trim later.

Attach the front to the cabinet assembly. Use finishing nails to attach the front to the sides (these nails will be covered with trim later.) From the back side, use 1 1/8" screws through the two front cleats to attach the front to the bottom and the workshelf.

Copyright

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Front and Side Trim

Page 6

Install the lower side and front trim pieces along the bottom with finishing nails as shown.

Install the vertical side and front trim pieces with finishing nails as shown.

Copyright

2005 by Robert E. Reedy, Vandalia, Ohio

Install Upper Horizontal Trim

Page 7

Install the top horizontal trim pieces with finishing nails as shown. This should leave a 1 1/8" space from the top of the cabinet panels so the Bar Top Assembly can fit over it.

Install the decorative frame molding with finishing nails as shown. Position the molding so the frame is centered side to side and slightly higher than centered top to bottom. The gap between the top of the frame and the top horizontal trim should be about 1" more than the gap between the bottom of the frame and the lower horizontal trim. If you center it top to bottom, it may actually look like it is too low because of an optical illusion.
Copyright
C

2005 by Robert E. Reedy, Vandalia, Ohio

Arrangement of Rear Trim

Page 8

Install the rear trim pieces with finishing nails as shown.

Copyright

2005 by Robert E. Reedy, Vandalia, Ohio

Install Brackets & Measure Side Rail Length

Page 9

Install the Foot Rail Brackets as shown. Your hardware may be diffferent, so be sure to take your own measurements. Position one brachet so the foot sets flat on the floor and measure the distance of the mounting holes from the floor. This should be about 5 1/2". The rest of the brackets must all be the same height. The rear edge of the side brackets should be two inches from the rear vertical trim. The front brackets should be centered side to side between the trim. Note the angle of the mounting screws. You can get the correct angle by trying it on some scrap wood. I recommend you leave these mounting screws slightly loose so the brackets can all sit freely on the floor.

2"

Place a piece of tubing in the front supports as shown and measure the distance "X". (The rear of the cabinet trim to the edge of the tubing.) This should be about nineteen or twenty inches. This will be the length of the tubing for the sides.
X

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Measure Front Rail Length - Assemble Rails

Page 10

Insert a piece of tubing in each side support as shown. Have someone help you hold them so they are parallel to the cabinet and the floor. Measure the distance "Y". This is the length of the front tubing.
Y

Assemble the rails as shown to the left. The end caps go into the rear of the side rail sections. I recommend completely assembling the rail with the screws provided in the kit and tighten all the screws enough so they make visible marks on the brass rail sections. Then, disassemble the rail and drill 3/16" holes in the rail where the screw marks are so the screws will all fit flush with the bracket surfaces, elbow collar surfaces, and at the end caps. Since the end caps are inserted into the ends of the rail sections, their screw heads will be on the outside of the rail section.
Copyright c 2005 by Robert E. Reedy, Vandalia, Ohio

Assemble the Armrest Molding

Page 11

The first step in assembling the top is to assemble the molding as shown above. Note: This drawing shows the molding in an upside down position.

The photos below show a couple of ways to attach the molding corners.

You can join the corners with pocket holes as shown in Figure 1. You'll need a small pocket hole jig for this. Note: Be sure to place the pocket holes so the screws dont come through the top surface of the molding. Shorter screws may be necessary. Apply glue and secure with pocket hole screws. You can secure the joints with finishing nails by temporarily securing the corners using some scrap plywood with pocket hole screws as shown in Figure 2. Drill two pocket holes on each of two sides of the plywood. Glue some 100 grit sandpaper to the surface of the scrap plywood where it contacts the lip of the molding (This makes it grip tighter.) Apply glue to the molding joint then secure the molding with the scrap plywood to hold the joint firmly together. Turn the assembly over and secure with two finishing nails as shown (Be sure to pre-drill the nail holes so you don't split the wood). Countersink the nails so you can fill with putty later. Then you can remove the scrap plywood. The soffit which will be added later will serve to re-enforce the corner joints.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Drill Pocket Holes in the Top

Page 12

Drill pocket holes on the bottom surface of the top as shown. The two pocket holes along the long edge are used to secure the top to the molding. These two holes will keep the top centered in the molding and still allow for expansion or contraction.

26"

2 1/4" 26"

2 1/4"

The pocket holes along the back and cutout are for mounting the trim. The ones that are not marked may be placed in approximately the position shown.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Rear Trim to the Top

Page 13

Attach the top trim with glue and pocket hole screws as shown above. To ensure the top surfaces of both the Trim and Top are flush, clamp both pieces to a flat surface before inserting pocket hole screws.

Trim Plywood Flat surface

This illustration shows how to clamp a piece of trim to plywood. One clamp holds the trim piece flush to a flat surface and the other clamp holds the plywood flat to the same surface. In this case, the plywood represents the bar top. To keep the pieces flush along the whole piece, you'll want to move the clamps close to each pocket hole as you insert the screws. This will ensure the trim is flush with the top surface.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Risers to the Top

Page 14

10 3/4" Risers 4 1/4" Risers 25" Risers

Apply some glue and arrange the risers on the underside of the top as shown. Attach with either 1 1/8" flathead screws or 1" finishing nails.
4 3/4" Risers

Note: Even though 1 1/8" screws won't penetrate the plywood, they may cause unsightly bumps on the top surface. To avoid this, pre-drill the screw holes in the plywood with a bit slightly larger than the inner diameter of the threaded section of the screws.

Countertop Riser 1" Screw 1 1/2" Screw Trim Soffit

The above illustration shows now the armrest molding, countertop, risers and soffit fit together.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Top to Molding & Attach End Soffit

Page 15

Attach the assembled top to the molding assembly with pocket hole screws as shown. Do not glue the top to the molding.

Attach the end soffit pieces to the molding with 1" flat head screws. Attach the end soffit pieces to the risers with 1 1/8" pan head screws.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Attach Center Soffit

Page 16

Attach the center soffit pieces to the outside edge of the molding with 1" pan head screws. Attach the center soffit pieces to the risers with 1 1/8" pan head screws.

54"

14 3/4"

This should leave an opening that is 54" between the end pieces of soffit and 14 3/4" between the center soffit and the rear trim. This is the size of the outside dimensions of the cabinet top and this opening must fit over the cabinet top.

This drawing shows an upsidedown view of how the cabinet and top are attached. Use two corner brackets on each end and three in the middle. You don't want to actually turn the bar upside down to attach the top, it may damage it. Spacing of the corner brackets is not critical. The cabinet trim is not shown for clarity.

Note: You should predrill the bracket screw holes in the top and use screws that go no more that 1/2" into the wood. Otherwise, the bracket screws may cause unsightly bumps on the top surface of the Bar Top.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Assemble Drawers
Page 17

Apply a little glue to the mating surfaces and assemble the drawer boxes.
Left Side Right Side

Back

Front

Step 1

Step 2

Step 3

Assemble the front, back, and right side with 1" long finishing nails as shown in Step 1. Insert the bottom as shown in Step 2. Attach the left side as shown in Step 3.

Drawer Slide

Step 4

Step 5

Support the drawer boxes with 1/2" thick strips of wood and attach the drawer fronts with 1 1/8" screws as shown in Step 4. This is necessary because the bottom of the front must be 1/2" below the bottom of the box so it will overlap the rear cabinet trim when installed. Next, attach the drawer slides as shown in Step 5.

Copyright c

2005 by Robert E. Reedy, Vandalia, Ohio

Assemble Wine Racks

Page 18

Apply a little glue to the mating surfaces and assemble the wine racks as shown.
4 1/2"
Pocket Holes

Step 1

Step 2

Mount the front to the base with pocket hole screws. The base and front are flush on the bottom and the base is centered between the edges of the front.
Back

Two edge dividers are mounted flush with sides of the base. The center one is centered and the other two are 4 1/2" from the edge of the base to the center of the dividers.

Attach the back to the base with finishing nails or screws as you prefer. Attach the drawer slides as shown with the screws that were provided with the drawer slides.
Step 3
Drawer Slide

This completes the assembly of your home bar. Be sure to countersink and fill all finishing nails holes before applying the finish.
Copyright c 2005 by Robert E. Reedy, Vandalia, Ohio

Cutout Suggestions (1)

Page 19

Left Front Panel

Small Shelf

14"

Divider

Divider Bar Top

Cabnit Side

Cabnit Side

Front Cleat Front Cleat

14" Cleat 14" Cleat

Kick Panel

Workshelf

Center Front Panel Bottom Direction of Grain:

41"

14" Cleat 14" Cleat

14" Cleat 14" Cleat

Wine Rack Bottom

Wine Rack Bottom

14" Cleat 14" Cleat 14" Cleat 14" Cleat 14" Cleat 14" Cleat 14" Cleat 14" Cleat 14" Cleat

Right Front Panel

These layout diagrams show how to cut the parts from two pieces of 3/4" oak plywood. Note: Since the Center Front Panel and Small Shelf are almost square, they have an indicator arrow and dimension line to ensure you have the grain oriented properly. The other parts are more obvious since they are not as close to being square. You can cut the small shelf a little larger than it's listed size with a jig saw and true it up with a table saw since it will still have one straight edge.
Copyright
C

2005 by Robert E. Reedy, Vandalia, Ohio

Cutout Suggestions (2)

Page 20

Center Soffit

End Soffit

End Soffit

Top Drawer Box Front Top Drawer Box Back Middle Drawer Box Front Middle Drawer Box Back

Top Drawer Box Side Top Drawer Box Side Middle Drawer Box Side Middle Drawer Box Side

Lower Drawer Box Front

Lower Drawer Box Side

Lower Drawer Box Back

Lower Drawer Box Side

Cutout diagrams for the soffit and drawer box parts from 1/2" oak plywood. Cutout diagrams for risers are not given as they may be made from scrap wood.

Drawer Bottom

Drawer Bottom

Drawer Bottom

24"

48"

The drawer bottoms are made from 1/4" hardboard.

Copyright

2005 by Robert E. Reedy, Vandalia, Ohio

Cutout Suggestions (3)

Page 21

Side Cutout Trim

Rear Countertop Trim

CornerTrim Fluted Trim Fluted Trim

CornerTrim

Side Cutout Trim

Rear Countertop Trim

Rear Top Horizontal Trim Back Corner Trim Vertical Divider Trim Raer Bottom Horizontal Trim

Back Corner Trim Vertical Divider Trim

Front Bottom Trim Front Top Trim

Bottom Deco trim Side Deco trim

CornerTrim CornerTrim
Side Deco trim

Top Deco trim

Wine Rack Side

Wine Rack Side

Side Trim Drawer Divider Trim Drawer Divider Trim

Side Trim

Side Trim Center Cutout Trim

Side Corner Trim Side Corner Trim

Side Trim

Wine Rack Front

Wine Rack Front

4"

Top Drawer Front

Middle Drawer Front

Lower Drawer Front

Top Half

Lower Drawer Front

Bottom Half

Wine Rack Divider Wine Rack Divider Wine Rack Divider

Wine Rack Divider Wine Rack Divider

6"

Wine Rack Side

Wine Rack Back

Wine Rack Back

Cutout diagrams for the parts that are made from solid oak.

If you're making two wine racks, you'll still need one more wine rack side and divider. Hopefully, you'll have some small pieces of oak lying around to make them from. Since these are inside parts, you could make them from some other material rather than buy an extra piece of oak. If so, you probably would want to make the rest of the inside wine rack parts from the same material too.
Copyright
C

2005 by Robert E. Reedy, Vandalia, Ohio

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Copyright 2005 by Robert E Reedy, Vandalia, Ohio