How to Build a Teak Bar Countertop
Materials and Tools:
one sheet 4'x8' 3/4" MDF core/teak laminate
one 12' solid teak 2"x6" (exotic woods come in various lengths and widths, we used an off-cut, damaged piece)
1-1/4" wood screws
1. Using the table saw, cut the sheet of MDF down to 92-1/2"x15-1/2" for the bar base.
2. With the pocket jig, drill a hole on three sides of the MDF every 12" on center.
3. Using the table saw, cut the 12' solid teak in half, length-wise, so you end up with two 2"x3" sections (we only used one piece for this project).
4. Use a draw knife to create a rounded, irregular edge on one side of the solid teak. Drag the knife across edge going against the wood grain.
5. Set the chop saw to a 45-degree angle and cut the 12' solid teak into three pieces – two at 15-1/2" (for the sides) to the short point and one at 92-1/2" to the short point.
6. Take the 92-1/2" piece of solid teak and clamp it to the MDF. Make sure the pocket holes are on top and the rounded edge of the solid teak should be on the bottom, towards the back.
7. Make slits for the biscuits using the plate joiner every 12 inches off center, so they are 6 inches in between each pocket hole.
8. Repeat this step for the two sides of the MDF.
9. Also, add a biscuit joint onto one side of each miter cut on the solid teak, so that the mitered edges can be joined together with biscuits.
10. Fill each slit on the solid teak with glue and insert a biscuit.
11. Add glue to the tops of each biscuit.
12. Secure the teak and MDF with wood screws by drilling into the pocket holes. This will add extra support to the bar top.
13. Turn the bar top over and distress the teak on top, giving the bar a nice uneven surface.