Build a Bar Using a Reclaimed Door For the Top

A salvaged glass-panel door is transformed into a unique bar top for an outdoor entertainment area.
HCCAN605_Bar-After_s4x3

HCCAN605_Bar-After_s4x3

Tools and Materials:

3/4” plywood
reclaimed door with glass panel
Brad nailer with 2” nails
two fluorescent light panels with switch plate and bulbs
four pre-finished bracket feet
composite light panel (cut to the size of the glass panel on the door)
wood glue
sander and sandpaper
wood putty
wood stain or paint and painting tools
polyurethane or marine-grade varnish (recommended for outdoor use)
clear silicone caulk
newel posts
table saw
miter saw
speed square and a tape measure

Steps:

HCCAN605_Door-before_s4x3

HCCAN605_Door-before_s4x3

1. Our found door measured 72” by 28” with a glass panel measuring 64” x 18”. Our measurements for the bar are all based off of the door. The size and shape of your bar will vary based on the door you’re able to find.

HCCAN605_Corner-trim_s4x3

HCCAN605_Corner-trim_s4x3

2. Add decorative trim around the sides and around edge of the door/bar top.

3. Build a simple light box from 3/4” plywood that will sit underneath the door/ bar top and above the bar. Our box measures 6” x 64” x 20”.

HCCAN605_Bar-Light-Box_s4x3

HCCAN605_Bar-Light-Box_s4x3

4. Center the fluorescent light panels into the bottom of the light box and secure with the included hardware. Drill a hole in the light box and feed the cords through the hole. We made one side of the light box sides removable to make it easy to change light bulbs.

HCCAN605_Buidling-Bar-Base_s4x3

HCCAN605_Buidling-Bar-Base_s4x3

5. Build the base of the bar from the 3/4” plywood. Our base measures 32” x 56“ x 13” with a 1-inch recessed bottom and a shelf sitting 15 inches from the bottom. Attach the four bracket feet to the bottom of the bar base with the included hardware.

HCCAN605_bar-base-with-top_s4x3

HCCAN605_bar-base-with-top_s4x3

6. Place the light box on the bar base and secure with wood glue and brad nails. Place the door/tabletop onto the light box and secure with wood glue and Brad nails.

HCCAN605_Placing-insert-in-door_s4x3

HCCAN605_Placing-insert-in-door_s4x3

7. Drop the composite light panel into the glass panel of the door. Secure this with a bead of silicone caulk around the edge of the panel.

8. Add newel posts to either side of the bar face for architectural detail.

9. Sand rough edges, fill in any gaps or holes with wood putty then stain or paint the bar. When the stain is dry, apply one to two coats of weatherproof varnish.

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