How to build a wooden bar with a fold-down serving tray

Building a wooden bar with a fold-down serving tray is a fun and practical woodworking project. It allows you to create a stylish and functional bar area for your home while saving space with the fold-down tray. Here’s a step-by-step guide to help you build your own wooden bar with a fold-down serving tray.

Materials Needed

• Wood (plywood, hardwood, or softwood depending on preference)
• Wood glue
• Screws and nails
• Hinges (for the fold-down tray)
• Sandpaper (various grits)
• Wood stain or paint (optional for finishing)
• Wood filler (if needed)
• Measuring tape
• Saw (table saw or circular saw)
• Drill and drill bits
• Screwdriver
• Clamps (optional, for added stability)
• Level

Step-by-Step Instructions

1. Design Your Bar

• First, decide on the size and layout of the bar. The dimensions will depend on the available space and the height of the bar (typically around 42 inches).
• Sketch the bar design, including the fold-down tray. Think about the function of the bar: Do you want shelves for storing bottles or glasses? Do you want a wine rack or a built-in cooler?
• Consider the type of wood you want to use. For a sturdy bar, hardwood like oak or maple is a good choice, but you can also use plywood for a more budget-friendly option.

2. Cut the Wood for the Bar Frame

• Measure and cut the pieces for the main structure of the bar. This includes the front, back, sides, and top of the bar.
• Cut the top piece to your desired length and width. The standard depth of the bar top is about 24 inches, but this can be customized to your preferences.
• For the sides and the back, cut the wood to fit the height and width of the bar.
• If you want extra storage, you can add shelves on the inside of the bar structure.

3. Assemble the Bar Frame

• Start assembling the frame of the bar by attaching the sides to the back piece using wood glue and screws. Ensure that the structure is square using a level.
• Attach the front piece to the sides and back of the bar frame to complete the basic structure. You can reinforce the joints with wood screws to ensure a solid and stable frame.
• If you’re adding shelves, install them at this stage by attaching horizontal support pieces to the sides, then placing the shelf boards on top.

4. Build the Fold-Down Serving Tray

• Cut a piece of wood that will serve as the serving tray. The size of the tray will depend on how large you want the serving area to be.
• Attach two sturdy hinges to one side of the tray. This will allow the tray to fold down and up with ease.
• Install the other side of the hinges on the front part of the bar frame. Make sure to align the hinges correctly to allow smooth folding and unfolding of the tray.
• You can also add a locking mechanism to keep the tray in place when it’s folded up, so it doesn’t accidentally drop down when not in use.

5. Add the Bar Top

• Once the frame and the tray are assembled, attach the top of the bar. The top should be securely fastened, and it should overhang the sides by at least a few inches for a more professional look.
• Use wood glue and screws to attach the top to the frame. Make sure the top is level before securing it in place.

6. Sand and Finish the Bar

• After the main structure is built, smooth all the edges and surfaces using sandpaper. Start with a coarse grit sandpaper and gradually move to a finer grit for a smooth finish.
• If you want to add color to the bar, apply a wood stain or paint to give it a polished look. This is optional, but staining or painting will help protect the wood from moisture and wear over time.
• You can also add a clear wood finish or polyurethane for added durability and protection.

7. Install the Serving Tray Mechanism

• If your fold-down tray needs additional support when in use, install a set of support legs or a chain that can hold the tray in place when it’s extended. This will keep the tray stable when it is being used.
• You can also add a small latch or lock to the fold-down tray so that it stays securely in place when it’s folded up.

8. Add Decorative Details

• Now that the structure is in place, you can add any decorative elements to the bar. This might include trim around the edges, a backsplash, or even a chalkboard section for writing down drink specials or the day’s menu.
• If you want to add extra functionality, consider installing a bottle opener or a small sink area to make the bar even more convenient.

9. Final Touches

• Check all the connections and ensure everything is secure. Test the fold-down tray to ensure it operates smoothly and stays in place when folded.
• Make any adjustments needed, such as tightening screws or applying extra finish to any rough areas.

Tips for Success

• Choose the Right Hinges: When selecting hinges for the fold-down tray, make sure they are heavy-duty enough to support the weight of the tray and anything you plan to place on it.
• Ensure Stability: The fold-down tray should lock in place when not in use to prevent it from accidentally dropping. Adding a safety latch or securing system will help.
• Customize Your Design: Feel free to add personal touches to the bar design, such as custom shelving, wine racks, or even LED lighting.

Conclusion

Building a wooden bar with a fold-down serving tray is an enjoyable project that will enhance your home. With a bit of planning, the right materials, and careful execution, you can create a stylish and functional bar that maximizes space and provides a great spot for entertaining guests. Be sure to take your time with each step, and don’t hesitate to customize the design to fit your needs and taste.

For more woodworking ideas and step-by-step guides, check out Ted’s Woodworking Course here.