Build an Outdoor Bar

We will begin by constructing the front and sides of the bar. We will first create frames for both the front and sides using 2" x 4"s and will then secure particle board panels over the frames. The bar in this project is 42" tall by 60" wide by 40" deep. You will be drilling several screws in this project. To make this process easier - first drill pilot holes for the screws in your frame using your Dremel Rotary Tool and a 150 1/8" Drill Bit.

Create the frame of your front panel by cutting two lengths of 38.5" and two lengths of 47" 2" x 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment. Place the guide near your measurement marks. Leave about an 1/8 inch between the guide and line to accommodate for the kerf of the wheel and its slight offset. Clamp the guide in place. Make your first pass, then flip the board over to complete the cut all the way through the 2x4 on your second pass.

Next, cut a particle board panel to secure behind the frame of the bar. Measure and mark an area of 51" by 40". Secure the particle board into place with a clamp. Using your Saw-Max tool with an SM500 wheel, cut out the panel. Start the tool slightly away from your particle board. Move the tool slowly through the work piece, letting the wheel do the work. Follow the notch at the top of the Saw-Max tool and ensure the line you marked is visible through the notch for the straightest cut.

Secure your frame behind the particle board panel you just cut. Lay the frame over the panel and align flush with the bottom edge leaving 1.5" overhang of particle board on the top and 1.5" reveal of 2" x 4" frame on either side. Place screws in all four corners and in the middle of each side of your frame from the particle board side to hide screws and to ensure the structure is sturdy.

Create the frames of your two side panels by cutting four lengths of 23" 2" by 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment. Refer to the technique on step two for the best way to cut your 2" by 4"

Next, cut two particle board panels to secure behind the side frames of the bar. Measure and mark an area of 29.25" by 40". Secure the particle board into place with a clamp. Using your Saw-Max tool with an SM500 wheel, cut out the panels.

Secure your panels behind the two side frames you created in step 6. Lay the frame over the panel and align flush with the bottom and back edge leaving 1.5" overhang of particle board on the top and 3/4" reveal of 2" x 4" frame on the front side. As you did for the front panel, place screws in all four corners and in the middle of each side of your frame to ensure the structure is sturdy.

Now it is time to secure the side panels to the front panel you just created. It is best if you have another set of hands for help here. Have someone help by holding up the front of your bar panel while you place the first side panel into position. Align one side panel at a time with the front panel. Your corners should align and slide into place with the overhang and reveal, you left on the side and front panels. Slide the two pieces together and secure with wood screws. Make sure that your screws hit the 2" x 4" joints and not the particle board. Start with one screw at the top making sure the side is aligned and then place one at the bottom and two in the center to ensure the structure is sturdy. Follow the same steps to secure the other side panel.

Remember that this is your project - have fun with it and make it personalized! As another idea - you can add brick or tile to desired area. You can cut these materials to size by using the SM510 Tile Wheel or the SM540 Masonry Wheel. Here, we added masonite brick to our bar. Since Masonite is a pressure-treated wood material that comes in sheets, it is a cost-effective way to spruce up your bar. We cut sheets of the masonite brick to size using the Saw-Max SM500 Wood and Plastic Wheel. To cut the sheet to size, clamp the portion you wish to cut on your workbench. Turn on your tool slightly away from the masonite and guide the tool slowly through the material. Secure the masonite to the front of your bar using your drill driver and wood screws.

Create the frame for your bar top by cutting two lengths of 30.75" and one length of 60" 2" by 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment. Refer to the technique on step two for the best way to cut your 2" x 4".

You are almost finished! Now that you have the structure of your bar in place, it is time to create the top of the bar. Measure and mark an area of 60" by 40". Secure the particle board into place with a clamp. Using your Saw- Max tool with an SM500 wheel, cut out the panel. As you did when cutting out the other panels for the bar - remember to start the tool slightly away from your particle board. Move the tool slowly through the work piece, letting the wheel do the work. Follow the notch at the top of the Saw-Max tool and ensure the line you marked is visible through the notch for the straightest cut. Be creative with the bar top material you choose - here we wanted to use the same material as the rest of the bar to create a cohesive look, but you could choose a hardwood panel if you wish. You will still be able to cut it using the Saw-Max and an SM500 wheel.

Secure your frame behind the particle board panel you just cut. Lay the 2" x 4" frame over the panel and align flush with the bottom edge leaving 6.5" overhang of particle board at the front of your bar top. Place screws in all four corners of the frame to secure the particle board.

Finally, secure your bar top into place. Set the top over the frame of your bar - have someone help you align the frame so that it fits tight against the particle board lip around the top of your front and side panels. Secure the top to the base from underneath using wood screws around the top edge of the particle board. Place a screw every 1' for added stability.

For added flair and functionality, create a 12" x 12" (or whatever size you like) cut-out in the bar top to set an ice bucket in using the Dremel Trio, a Multi-Purpose Cutting Bit TR563 and a circle-cutting attachment. Mark the pilot hole 16" down from the front and side edges so that the top remains sturdy. Use the Trio tool to plunge cut the pilot hole. Mount and adjust the guide so the distance between the bit and the guide's pivot point is 6". You are done! Now add finish to your bar. Here, we added a varnish to make the material slightly more weather-resistant.