How to Assemble & Install Main Bar Top Kits

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Remove the bar top parts from the box and lay them out on your work bench to familiarize yourself with how they go together. Prepare the tools needed to complete the job; a drill, drill bits and countersink, 1-1/4” x #6 or #8 wood screws, wood glue, bar and C clamps and a clean damp cloth. Determine if you want to cut and fit all the planks first or cut, fit and install each plank as you go; whatever way is easier for you.

Next, miter and or cut to size the 6” wide plank and place it 1-9/16” from the front edge of the bar top using C clamps to hold it in place. Trace the perimeter of this plank with a pencil and remove it. Then drill and counter sink holes through the plywood sub top in a zigzag pattern about ¾” inside your pencil mark, remove any wood chips or debris from the sub top and install this plank using 1-1/4” x #6 or #8 wood screws only (NO GLUE).

Cut to length and or miter the 5” wide center plank, tap it into place to check fitment and repeat the drilling process described above. When installing this plank run a small bead of wood glue on top of the tongue only and tap it back into place with a rubber mallet or hammer. Use a small bar clamp across the planks to draw tight any gaps in the seam and install using 1-1/4” x #6 or #8 wood screws as previously described.

Now you are ready to install the third plank and optional fourth plank – if required – by repeating the same process. Once you have done this use the clean damp cloth to remove the excess glue and let it dry several hours. When the glue is dry, sand clean with a random orbit or vibrating sander to remove excess glue finger prints and debris.

You are now ready to install your bar rail molding, inside edge trim or glass rail and drip edge and begin to finish the wood bar top. Please refer to our “How to finish your bar rail molding” for tips on finishing.

It is also possible to attach the bar top planks from the top by counter sinking screws in the planks and installing matching wood plugs over the screw heads. (click on images to enlarge)

1 bar top2 bar top

 

 

 

 

 

If making a 10’ or longer bar top, use multiple kit combinations to achieve the required length by alternating the joints of the planks as shown below. You can use bisquet joints in the ends of the planks where they meet as an option. For customers requiring a wider main bar top or for those not using the glass rail and drip edge option, we offer our main bar top kits with an extra 5” wide plank for a 21” width as shown below. (click on images to enlarge)

3 bar top4 bar top

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Posted in: Bar Building, Bar Parts

4 Responses

  1. Phil DiMitri says:

    Why do you not recommend using wood glue to attach the planks to to the sub top?

    • saleshardwoods says:

      The solid wood main bar top is NOT glued to the sub-top to allow for expansion. Use screws only and drill a slightly larger hole than the diameter of the screw. I will respond directly to your email as well.
      Thank you for considering Hardwoods Incorporated – The Hardwoods Team.

  2. Wood-Pro says:

    What is the best methd used to attach the completed bar top assembly to the base cabinet.

    • Amanda says:

      Once the main bar top kit is installed onto the plywood sub top, the entire assembly can be attached to base cabinets or bar wall with wood screws from underneath. Small angle brackets or continuous metal angles may also be used. Please contact us if you need assistance.

Leave a Reply

Hi Paul.

The bar rail turned out fantastic.  It’s 21ft of goodness.  Stain turned out great as well.  We just need to finish the project and we’ll take completion pics that will definitely showcase the bar rail and send them to you.

What we received was fantastic.  Your videos also helped in making sure my miters are tight and look great.  As an interesting note and one that you might also be interested in posting is…

We originally ordered bar rail from a big box chain home improvement store.  It was back ordered, so I cancelled and went shopping and found Hardwoods Incorporated.  Which I received quite promptly.  Shortly after, we received the big box store’s bar rail because they couldn’t cut off the order.  While we had to take their rail back, it gave us the opportunity to see their product and yours…and I’m telling you, you guys hit a home run in comparison.  I’m so glad our original order from a big box company was back ordered.  For anyone needing bar rail or related molding, I’ll never refer them to anyone else.

You guys and your products are fantastic.

Cody W. – Big Spring, Texas

08/05/2022

BR475 Red Oak Bar Rail Molding

The 450 bar rail was exactly as advertised. High quality product that looks great installed. I really appreciate the consultations by phone to make sure I got what I needed!

Bill S. – Mitchellville, Maryland

06/11/2020

BR450 Bar Rail Molding