The purpose of the project is to design and build a bar at
The appearance will be designed to blend the knotty pine used in the adjacent window trim and kitchen cabinets with the iroco hardwood used in the kitchen window trim, counter edge, and backsplash. The visual attributes will be a contrast of the soft rounded lines of the pine cabinet and the hard angular lines of the hardwood edges and post as the bar top extends out from the cabinet.
The primary structural attribute will be sturdiness and solid wood will be used as much as possible.
Total material cost: about $300.
Day 1 – Saturday, Nov. 1
Getting the material to
Day 2 – Sunday, Nov. 2
Completed the cabinet frame and shelves.
Day 3 – Saturday, Nov. 8
I decided to stay on the island (with Quinn & Riley) through the weekend and catch the Wednesday ferry. Dave Peters donated his time today, meeting me for the crossing and returned on the ferry.
Dave picked out some good pieces of the knotty pine tongue and groove paneling and assembled the two cabinet side panels.
We mounted the post to the floor by first screwing the hanger bolt (lag end) through the Pergo flooring, the sub-floor, and into a 2x4 mounted between joists under the sub-floor. We drilled a hole into the bottom of the post to accommodate the bolt end of the hanger bolt and attached the tee nut. After filling the hole with epoxy, we screwed the post onto the hanger bolt. We then screwed two ¼” x 4” lag screws into the post from the bottom.
We then attached the ¾” MDF sheet to the cabinet and the post with glue and six lag screws to the cabinet frame and two lag screws to the post (all counter-sunk).
Day 4 – Sunday, Nov. 9
I decided to add a beam between the cabinet and the post to beef things up in the center of the bar top. I attached a joist hanger to the cabinet frame and supported the 2x4 beam on the post side with a hardwood block. Cabinet screws were added from the top and the beam was wrapped with knotty pine.
The cabinet panels were then cut to fit and attached. The birch plywood was glued and clamped to the MDF and left overnight to dry.
Day 5 – Monday, Nov. 10
Cut the 45 degree corners on the cabinet top with a circular saw, finished the cabinet trim, and mounted the cabinet door. Also cut the self-edge pieces from the iroco to a width a 2 ¼”.
Day 6 – Tuesday, Nov. 11
Formed the self-edge on router table by champhering both top edges and adding a 1 ½” x ¼” dado in the center for mounting to the MDF and plywood. Mounted the self-edge with glue & brads.
Also added base trim to the cabinet and post. Finished everything with Danish oil.
Day 7 – Wednesday, Nov. 12
Attached the foot rails, did the final sanding and added a second coat of Danish oil, then spent the rest of the day cleaning up.
Final task for later: Add a hard finish to the bar top.