Building a wooden outdoor bar is a fun project that can add a touch of craftsmanship and style to your backyard or patio. When constructing the bar, it’s important to ensure it is both functional and durable, especially since it will be exposed to the elements. Weatherproofing the bar will protect it from the sun, rain, and humidity, making sure it lasts for years. Below is a step-by-step guide on how to build a wooden outdoor bar, with a focus on weatherproofing it properly.
Materials and Tools Needed
Materials:
- Pressure-treated lumber (for the frame)
- Cedar or redwood (for the bar’s outer surface; these woods are naturally resistant to decay)
- Exterior-grade plywood (for the bar’s top or shelves)
- Exterior wood screws
- Wood glue (for joints)
- Outdoor stain or paint
- Waterproof sealant
- Epoxy resin (optional, for extra weatherproofing)
- Weatherproofing wood finish
- Stainless steel or galvanized hardware (for screws and brackets)
- Outdoor-grade caulking
Tools:
- Circular saw or miter saw
- Drill and drill bits
- Screwdriver
- Tape measure
- Wood clamps
- Sandpaper or power sander
- Paintbrush or spray gun (for finishing)
- Safety goggles and gloves
Step-by-Step Instructions
1. Design and Plan Your Bar
Start by designing your outdoor bar, ensuring you have enough space to accommodate it in your desired location. Common dimensions for outdoor bars are about 6 feet long, 3 feet high, and 2 feet deep, but you can adjust based on your space and needs. Create a simple sketch or plan that includes:
- The frame and support structure
- The top (whether flat or with shelves)
- The weatherproofing techniques you’ll use
2. Prepare and Cut the Lumber
Once you’ve finalized your design, measure and cut the lumber for the bar’s frame. Use pressure-treated lumber for the base, as it is designed to resist moisture, decay, and insects. This will be the foundation that will support the rest of the structure.
Cut the following pieces for the frame:
- Two long vertical supports for the sides
- Shorter crosspieces for the front and back
- A top piece or several boards if you’re making a larger top
If you’re using cedar or redwood for the exterior surface, cut those boards to the desired width and length as well.
3. Build the Frame
Start by assembling the frame of the bar. Use wood glue at all the joints and reinforce them with screws. You can use corner brackets for added stability, especially if the bar will be in a windy area. Make sure the frame is level and square as you assemble it.
4. Install the Top Surface
The top of the bar can be made from exterior-grade plywood. Cut it to fit the frame, and screw it down securely. If you want a more decorative look, you can use individual boards made from cedar or redwood to cover the plywood. Ensure there are no gaps between the boards to prevent water from seeping through.
If you’re building shelves under the bar, install them at this stage using the same methods—wood glue and screws.
5. Sand the Wood Smooth
Once the frame and surface are assembled, sand all surfaces to smooth out any rough edges or splinters. This will help your wood absorb the stain or weatherproofing products more evenly. Pay extra attention to the edges, especially around the top of the bar, as these areas will get a lot of use.
6. Weatherproof the Wood
To weatherproof your wooden outdoor bar, apply an outdoor-grade wood stain or paint that includes UV protection. Look for a product that is specifically designed for outdoor use and offers water resistance. You can also choose a tinted finish to enhance the natural wood color while adding a layer of protection.
Staining: Apply a coat of wood stain and allow it to soak into the wood. Let it sit for about 15–20 minutes, then wipe off any excess stain. Allow it to dry completely before applying a second coat.
Sealing: After staining, apply a weatherproof sealant to create a moisture barrier. You can use an oil-based exterior sealant or epoxy resin for the best protection. Epoxy is especially effective for bar tops, as it creates a thick, durable, water-resistant layer.
Paint: If you prefer a painted look, use an exterior-grade paint formulated for outdoor use. Be sure to apply a primer first, especially if you’re working with untreated wood.
7. Apply Additional Protective Layers
Once the main weatherproofing layers have dried, consider applying a final top coat of clear waterproofing finish. This will help protect the wood from rain and humidity. It’s a good idea to choose a finish that is UV-resistant as well, as the sun’s rays can cause wood to dry out and fade over time.
For the top of the bar, a thick epoxy resin coat can be an excellent option. It will create a glass-like finish that is waterproof and resistant to scratches and stains.
8. Install Hardware and Final Touches
Install any necessary hardware, such as bottle holders, footrests, or hooks for hanging towels and bar tools. Use stainless steel or galvanized screws to prevent rusting. You can also add finishing touches like outdoor cushions for seating or a small overhang for extra shade.
9. Maintain the Bar
Even with weatherproofing, it’s important to regularly maintain the bar to ensure its longevity. Reapply sealant or stain annually, especially after a harsh winter. Clean the bar regularly and inspect for any signs of damage or wear.
Extra Tips for Enhancing Durability:
- If you live in an area with particularly harsh weather, consider adding a weather-resistant cover to your bar during the off-season. This will protect the wood from extreme sun and rain.
- Elevate the base of the bar slightly to prevent water from pooling underneath, which could lead to rot.
- Use a wood treatment specifically designed for outdoor furniture to provide additional protection against mold and mildew.
Conclusion
Building a wooden outdoor bar with proper weatherproofing is a rewarding project that can turn your backyard into a fantastic entertainment space. By using the right materials, following the proper construction techniques, and applying multiple layers of weatherproofing, you can ensure your bar lasts for years, even in the face of the elements. Remember to maintain the bar regularly, and it will remain a centerpiece of your outdoor gatherings.
For further woodworking projects, including how to build more outdoor furniture and other creative designs, check out Teds Woodworking Course here.