Bobs plans 6 Foot Home Bar User manual

www.BobsPlans.com
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 ¾”
oak veneered plywood. The trim and drawer fronts, from ¾” 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, you’ll 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

Materials You Will Need
Two Sheets of ¾” Oak Veneer Plywood - See Cutout Suggestions (1)
One Sheet of ½” Oak Veneer Plywood - See Cutout Suggestions (2)
One fourth Sheet of ¼” Hardboard - See Cutout Suggestions (2)
Four 5 ½” by 8’ by ¾” Oak Boards
One 6 ½” by 8’ by ¾” 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 ½” 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 you’ll 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 isn’t 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.

53/4"
161/4"
223/4"101/2"
17"
Attachthreecleatswithdrawerslidestotheleftsideasshownabove.Attachtwo
cleatswithdrawerslidestoleftdividerpanelasshownabove.Note:Thebottom
cleatanddrawerslidefortheleftdividerisattachedtothebottomwithpocketholes
later.Itwillthenprovideawaytoattachtheleftdividertothebottom.
Lowestpartofdrawerslideis
flushwithbottomofwood
Ifyouwillbeaddingdrawerstoyourbar,attach
thedrawerslidestocleatsasshown.Threemust
havetherollerontherightandthreemusthave
therollerontheleft.Thelowestpartofthe
drawerslidemustbeflushwiththebottomof
thecleat.Therollersectionmustprotrudepast
theendofthecleatsby3/4"(thethicknessofthe
trim).
Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
AttachDrawerSlides
Page1

Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
AttachWineRackSlides-AssembleBottom
Page2
143/4"
9"
Ifyouwillbeincludingwineracks,in
yourbar,attachthedrawerslidestothe
dividerpanelsasshown.Note:thedrawer
slidesforthewineracksdoNOT
protrude3/4"pasttheedgeofthedivider
panels.Thisisbecausethewinerack
frontswillbeflushwiththeopening
whilethedrawerfrontswillbeonthe
outsideoftheopening.
Attachtwocleatstotheendsofthebottomsurfacewithpocketholescrews.These
cleatsareflushtotheedgesofthebottom.
Attachthecleatstothetopsurfaceofthebottomplate
asshown.Pocketholessidesshouldbeplaced16"
fromtheendswithpocketholesidesfacingeachother
asshown.(Thesecleatsareusedformountingthe
verticalpanelstothebottomsurface.)

Frontcleat
Attachtheverticaldividersto
thecleatsasshown.Attachthe
frontcleatbetweenthepanelsas
shownwithpocketholescrews.
Turntheassemblyupsidedown
andattachthekickpanelas
shown
withpocketholescrews.Note:
thepocketholescrewsareonthe
backsideofkickpanel.
Page3
AttachVerticalDividers&KickPanel
Screwsonthisside.
Copyright
C
2005byRobertE.Reedy,Vandalia,Ohio

Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
AttachSidePanelsandWorkShelf
Page4
Attachthesidepanelsto
thebottomcleatswith
11/4"screws.
Now,attachthefourcleatstothe
bottomsideoftheworkshelfwith
pocketholescrewsasshown.The
endcleatshavepocketholes
facingout.Themiddlecleatshave
thepocketholesfacingeachother.
Thepocketholesideofthemiddle
cleatsareplaced16"fromthe
endsoftheworkshelf.
Placetheworkshelf(withcleats
attached)ontopofthevertical
dividersandsecureittothesides
anddividerswith11/4"screws
throughthecleats.
Attachtheupperfrontcleat
betweenthedividerswithpocket
holescrews.
Attachthesmallshelftothecleatswithfinishingnails.

Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
AssembleFront&SidePanels
Page5
Assemblethethreefrontpiecesasshownand
securewithpocketholescrews.Thesescrews
willbecoveredwithtrimlater.
Attachthefronttothe
cabinetassembly.Use
finishingnailstoattachthe
fronttothesides(these
nailswillbecoveredwith
trimlater.)Fromtheback
side,use11/8"screws
throughthetwofrontcleats
toattachthefronttothe
bottomandtheworkshelf.

Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
Page6
Installtheverticalsideandfronttrimpieceswithfinishingnailsasshown.
Installthelowersideandfront
trimpiecesalongthebottomwith
finishingnailsasshown.
AttachFrontandSideTrim

InstallUpperHorizontalTrim
Page7
Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
Installthedecorativeframemoldingwithfinishingnailsasshown.Positionthe
moldingsotheframeiscenteredsidetosideandslightlyhigherthancenteredtopto
bottom.Thegapbetweenthetopoftheframeandthetophorizontaltrimshouldbe
about1"morethanthegapbetweenthebottomoftheframeandthelower
horizontaltrim.Ifyoucenterittoptobottom,itmayactuallylooklikeitistoolow
becauseofanopticalillusion.
Installthetophorizontaltrimpieceswith
finishingnailsasshown.Thisshould
leavea11/8"spacefromthetopofthe
cabinetpanelssotheBarTopAssembly
canfitoverit.

Copyright2005byRobertE.Reedy,Vandalia,Ohio
C
ArrangementofRearTrim
Page8
Installthereartrimpieceswithfinishingnailsasshown.

InstallBrackets&MeasureSideRailLength
Page9
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Placeapieceoftubinginthe
frontsupportsasshownand
measurethedistance"X".(The
rearofthecabinettrimtothe
edgeofthetubing.)Thisshould
beaboutnineteenortwenty
inches.
Thiswillbethelengthofthe
tubingforthesides.
InstalltheFootRailBracketsasshown.Yourhardwaremaybe
diffferent,sobesuretotakeyourownmeasurements.Position
onebrachetsothefootsetsflatonthefloorandmeasurethe
distanceofthemountingholesfromthefloor.Thisshouldbe
about51/2".Therestofthebracketsmustallbethesameheight.
Notetheangleofthemountingscrews.
Youcangetthecorrectanglebytrying
itonsomescrapwood.Irecommend
youleavethesemountingscrews
slightlyloosesothebracketscanallsit
freelyonthefloor.
Therearedgeofthesidebrackets
shouldbetwoinchesfromtherear
verticaltrim.Thefrontbrackets
shouldbecenteredsidetoside
betweenthetrim.
2"
X

MeasureFrontRailLength-AssembleRails
Page10
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Insertapieceoftubingineach
sidesupportasshown.Have
someonehelpyouholdthemso
theyareparalleltothecabinetand
thefloor.Measurethedistance
"Y".
Thisisthelengthofthefront
tubing.
Sincetheendcapsareinsertedintotheendsoftherailsections,
theirscrewheadswillbeontheoutsideoftherailsection.
Assembletherailsasshownto
theleft.Theendcapsgointo
therearofthesiderailsections.
Irecommendcompletely
assemblingtherailwiththe
screwsprovidedinthekitand
tightenallthescrewsenoughso
theymakevisiblemarksonthe
brassrailsections.Then,
disassembletherailanddrill
3/16"holesintherailwherethe
screwmarksaresothescrews
willallfitflushwiththebracket
surfaces,elbowcollarsurfaces,
andattheendcaps.
Y

AssembletheArmrestMolding
Page11
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Thefirststepinassemblingthetopis
toassemblethemoldingasshown
above.
Note:Thisdrawingshowsthe
moldinginanupsidedownposition.
Thephotosbelowshowacoupleofwaystoattachthemoldingcorners.
YoucanjointhecornerswithpocketholesasshowninFigure1.You'llneedasmallpocketholejigfor
this.Note:Besuretoplacethepocketholessothescrewsdon’tcomethroughthetopsurfaceofthe
molding.Shorterscrewsmaybenecessary.Applyglueandsecurewithpocketholescrews.
Youcansecurethejointswithfinishingnailsbytemporarilysecuringthecornersusingsomescrap
plywoodwithpocketholescrewsasshowninFigure2.Drilltwopocketholesoneachoftwosidesof
theplywood.Gluesome100gritsandpapertothesurfaceofthescrapplywoodwhereitcontactsthelip
ofthemolding(Thismakesitgriptighter.)Applygluetothemoldingjointthensecurethemoldingwith
thescrapplywoodtoholdthejointfirmlytogether.
Turntheassemblyoverandsecurewithtwofinishingnailsasshown(Besuretopre-drillthenailholes
soyoudon'tsplitthewood).Countersinkthenailssoyoucanfillwithputtylater.Thenyoucanremove
thescrapplywood.Thesoffitwhichwillbeaddedlaterwillservetore-enforcethecornerjoints.

DrillPocketHolesintheTop
Page12
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Drillpocketholesonthebottomsurfaceofthetopas
shown.Thetwopocketholesalongthelongedgeare
usedtosecurethetoptothemolding.Thesetwoholes
willkeepthetopcenteredinthemoldingandstill
allowforexpansionorcontraction.
26"
26"
21/4"
21/4"
Thepocketholesalongthebackandcutout
areformountingthetrim.Theonesthatare
notmarkedmaybeplacedin
approximatelythepositionshown.

AttachRearTrimtotheTop
Page13
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Thisillustrationshowshowtoclampapieceoftrimtoplywood.Oneclampholds
thetrimpieceflushtoaflatsurfaceandtheotherclampholdstheplywoodflatto
thesamesurface.Inthiscase,theplywoodrepresentsthebartop.Tokeepthe
piecesflushalongthewholepiece,you'llwanttomovetheclampsclosetoeach
pocketholeasyouinsertthescrews.Thiswillensurethetrimisflushwiththetop
surface.
Attachthetoptrimwithglueandpockethole
screwsasshownabove.Toensurethetop
surfacesofboththeTrimandTopareflush,
clampbothpiecestoaflatsurfacebefore
insertingpocketholescrews.
Flatsurface
Plywood
Trim

AttachRiserstotheTop
Page14
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Theaboveillustrationshowsnowthearmrestmolding,countertop,risersand
soffitfittogether.
Countertop
Riser
Soffit
Trim
1"Screw
11/2"Screw
25"Risers
103/4"Risers
43/4"Risers
Applysomeglueandarrangetheriserson
theundersideofthetopasshown.Attach
witheither11/8"flatheadscrewsor1"
finishingnails.
Note:Eventhough11/8"screwswon'tpenetratetheplywood,theymaycause
unsightlybumpsonthetopsurface.Toavoidthis,pre-drillthescrewholesinthe
plywoodwithabitslightlylargerthantheinnerdiameterofthethreadedsection
ofthescrews.
41/4"Risers

AttachToptoMolding&AttachEndSoffit
Page15
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Attachtheendsoffitpiecestothemolding
with1"flatheadscrews.Attachtheend
soffitpiecestotheriserswith11/8"pan
headscrews.
Attachtheassembledtoptothemolding
assemblywithpocketholescrewsas
shown.Donotgluethetoptothemolding.

AttachCenterSoffit
Page16
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
54"
143/4"
Attachthecentersoffitpiecestothe
outsideedgeofthemoldingwith1"
panheadscrews.Attachthecenter
soffitpiecestotheriserswith11/8"
panheadscrews.
Thisshouldleaveanopeningthatis54"betweentheendpiecesofsoffitand143/4"
betweenthecentersoffitandthereartrim.Thisisthesizeoftheoutsidedimensionsofthe
cabinettopandthisopeningmustfitoverthecabinettop.
Thisdrawingshowsanupsidedownviewofhowthe
cabinetandtopareattached.Usetwocornerbracketson
eachendandthreeinthemiddle.Youdon'twantto
actuallyturnthebarupsidedowntoattachthetop,
itmaydamageit.
Spacingofthecornerbrackets
isnotcritical.Thecabinettrim
isnotshownforclarity.
Note:Youshouldpredrillthebracketscrewholesinthetopandusescrewsthatgonomore
that1/2"intothewood.Otherwise,thebracketscrewsmaycauseunsightlybumpsonthetop
surfaceoftheBarTop.

AssembleDrawers
Page17
Copyright2005byRobertE.Reedy,Vandalia,Ohio
c
Step2Step3
LeftSide
Step1
RightSide
Front
Back
Step5 Step4
DrawerSlide
Supportthedrawerboxeswith1/2"thickstripsofwoodandattachthedrawerfronts
with11/8"screwsasshowninStep4.Thisisnecessarybecausethebottomofthe
frontmustbe1/2"belowthebottomoftheboxsoitwilloverlaptherearcabinettrim
wheninstalled.Next,attachthedrawerslidesasshowninStep5.
Applyalittlegluetothematingsurfacesandassemblethedrawerboxes.
Assemblethefront,back,andrightsidewith1"longfinishingnailsasshownin
Step1.InsertthebottomasshowninStep2.AttachtheleftsideasshowninStep3.