Build an Outdoor Bar (Expert) DIY Project

Building an outdoor bar is a great project to make your backyard party-ready. For blueprints and detailed instructions on this advanced project, click on 'Download a PDF' below.
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Step 2:  Create the frame of your front panel by cutting two lengths of 38.5" and two lengths of 47" 2" x 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment.  Place the guide near your measurement marks.  Leave about a 1/8 inch between the guide and line to accommodate for the kerf of the wheel and its slight offset.  Clamp the guide in place.  Make your first pass, then flip the board over to complete the cut all the way through the 2x4 on your

Step Create the frames of your two side panels by cutting four lengths of by using the Saw-Max tool with the flush cutting blade and the cutting guide attachment. Refer to the technique on step two for the best way to cut your by

Step 3:  Next, cut a particle board panel to secure behind the frame for of the bar.  Measure and mark an area of 51" by 40".  Secure the particle board into place with a clamp.  Using your Saw-Max tool with an SM500 wheel, cut out the panel.  Start the tool slightly away from your particle board.  Move the tool slowly through the workpiece, letting the wheel do the work.  Follow the notch at the top of the Saw-Max tool and ensure the line you marked is visible through the notch for the…

Step Next, cut two particle board panels to secure behind the side frames of the bar. Measure and mark an area of by Secure the particle board into place with a clamp. Using your Saw-Max tool with an wheel, cut out the panels.

Step 5:  Create the frames of your two side panels by cutting four lengths of 23" 2" by 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment. Refer to the technique on step two for the best way to cut your 2" by 4"

Step Create the frames of your two side panels by cutting four lengths of by using the Saw-Max tool with the flush cutting blade and the cutting guide attachment. Refer to the technique on step two for the best way to cut your by

Step 6:  Next, cut two particle board panels to secure behind the side frames of the bar.  Measure and mark an area of 29.25" by 40".  Secure the particle board into place with a clamp.  Using your Saw-Max tool with an SM500 wheel, cut out the panels.

Step Next, cut two particle board panels to secure behind the side frames of the bar. Measure and mark an area of by Secure the particle board into place with a clamp. Using your Saw-Max tool with an wheel, cut out the panels.

Step 10:  Create the frame for your bar top by cutting two lengths of 30.75" and one length of 60" 2" by 4" using the Saw-Max tool with the flush cutting blade SM600 and the 2x4 cutting guide attachment. Refer to the technique on step two for the best way to cut your 2" x 4".

Step Create the frames of your two side panels by cutting four lengths of by using the Saw-Max tool with the flush cutting blade and the cutting guide attachment. Refer to the technique on step two for the best way to cut your by

Step 11:  You are almost finished!  Now that you have the structure of your bar in place, it is time to create the top of the bar.  Measure and mark an area of 60" by 40".  Secure the particle board into place with a clamp.  Using your Saw-Max tool with an SM500 wheel, cut out the panel.  As you did when cutting out the other panels for the bar- remember to start the tool slightly away from your particle board.  Move the tool slowly through the workpiece, letting the wheel do the work…

Step Next, cut two particle board panels to secure behind the side frames of the bar. Measure and mark an area of by Secure the particle board into place with a clamp. Using your Saw-Max tool with an wheel, cut out the panels.

Step 14:  For added flair and functionality, create a 12" x 12" (or whatever size you like) cut-out in the bartop to set an ice bucket in using the Dremel Trio, a Multi-Purpose Cutting Bit TR563 and a circle-cutting attachment.  Mark the pilot hole 16" down from the front and side edges so that the top remains sturdy.  Use the Trio tool to plunge cut the pilot hole.  Mount and adjust the guide so the distance between the bit and the guide's pivot point is 6".  You are done!  Now add finish…

Step 14: For added flair and functionality, create a 12" x 12" (or whatever size you like) cut-out in the bartop to set an ice bucket in using the Dremel Trio, a Multi-Purpose Cutting Bit TR563 and a circle-cutting attachment. Mark the pilot hole 16" down from the front and side edges so that the top remains sturdy. Use the Trio tool to plunge cut the pilot hole. Mount and adjust the guide so the distance between the bit and the guide's pivot point is 6". You are done! Now add finish…

Step 1:  We will begin by constructing the front and sides of the bar.   We will first create frames for both the front and sides using 2" x 4"s and will then secure particle board panels over the frames. The bar in this project is 42" tall by 60" wide by 40" deep.     You will be drilling several screws in this project.  To make this process easier- first drill pilot holes for the screws in your frame using your Dremel Rotary Tool and a 150 1/8" Drill Bit.

Step 1: We will begin by constructing the front and sides of the bar. We will first create frames for both the front and sides using 2" x 4"s and will then secure particle board panels over the frames. The bar in this project is 42" tall by 60" wide by 40" deep. You will be drilling several screws in this project. To make this process easier- first drill pilot holes for the screws in your frame using your Dremel Rotary Tool and a 150 1/8" Drill Bit.

Step 4:  Secure your frame behind the particle board panel you just cut.  Lay the frame over the panel and align flush with the bottom edge leaving 1.5" overhang of particle board on the top and 1.5" reveal of 2" x 4" frame on either side. Place screws in all four corners and in the middle of each side of your frame from the particle board side so hide screws and to ensure the structure is sturdy.

Step 4: Secure your frame behind the particle board panel you just cut. Lay the frame over the panel and align flush with the bottom edge leaving 1.5" overhang of particle board on the top and 1.5" reveal of 2" x 4" frame on either side. Place screws in all four corners and in the middle of each side of your frame from the particle board side so hide screws and to ensure the structure is sturdy.

Step 7:  Secure your panels behind the two side frames you created in step 6.  Lay the frame over the panel and align flush with the bottom and back edge leaving 1.5" overhang of particle board on the top and 3/4" reveal of 2" x 4" frame on the front side.     As you did for the front panel, place screws in all four corners and in the middle of each side of your frame to ensure the structure is sturdy.

Step 7: Secure your panels behind the two side frames you created in step 6. Lay the frame over the panel and align flush with the bottom and back edge leaving 1.5" overhang of particle board on the top and 3/4" reveal of 2" x 4" frame on the front side. As you did for the front panel, place screws in all four corners and in the middle of each side of your frame to ensure the structure is sturdy.

Step 8:  Now it is time to secure the side panels to the front panel you just created. It is best if you have another set of hands for help here.  Have someone help by holding up the front of your bar panel while you place the first side panel into position. Align one side panel at a time with the front panel. Your corners should align and slide into place with the overhang and reveal you left on the side and front panels. Slide the two pieces together and secure with wood screws.  Make sure

Step 8: Now it is time to secure the side panels to the front panel you just created. It is best if you have another set of hands for help here. Have someone help by holding up the front of your bar panel while you place the first side panel into position. Align one side panel at a time with the front panel. Your corners should align and slide into place with the overhang and reveal you left on the side and front panels. Slide the two pieces together and secure with wood screws. Make sure

Step 9:  Remember that this is your project- have fun with it and make it personalized! As another idea- you can add brick or tile to desired area.  You can cut these materials to size by using the SM510 Tile wheel or the SM540 Masonry Wheel. Here, we added masonite brick to our bar.  Since Masonite is a pressure-treated wood material that comes in sheets, it is a cost-effective way to spruce up your bar.  We cut sheets of the masonite brick to size using the Saw-Max SM500 Wood and Plastic…

Step 9: Remember that this is your project- have fun with it and make it personalized! As another idea- you can add brick or tile to desired area. You can cut these materials to size by using the SM510 Tile wheel or the SM540 Masonry Wheel. Here, we added masonite brick to our bar. Since Masonite is a pressure-treated wood material that comes in sheets, it is a cost-effective way to spruce up your bar. We cut sheets of the masonite brick to size using the Saw-Max SM500 Wood and Plastic…

Step 12:  Secure your frame behind the particle board panel you just cut.  Lay the 2" x 4" frame over the panel and align flush with the bottom edge leaving 6.5" overhang of particle board at the front of your bartop. Place screws in all four corners of the frame to secure the particle board.

Step 12: Secure your frame behind the particle board panel you just cut. Lay the 2" x 4" frame over the panel and align flush with the bottom edge leaving 6.5" overhang of particle board at the front of your bartop. Place screws in all four corners of the frame to secure the particle board.

Step 13:  Finally, secure your bartop into place.  Set the top over the frame of your bar- Have someone help you align the frame so that it fits tight against the particle board lip around the top of your front and side panels. Secure the top to the base from underneath using wood screws around the top edge of the particle board. Place a screw every 1' for added stability

Step 13: Finally, secure your bartop into place. Set the top over the frame of your bar- Have someone help you align the frame so that it fits tight against the particle board lip around the top of your front and side panels. Secure the top to the base from underneath using wood screws around the top edge of the particle board. Place a screw every 1' for added stability

Building an outdoor bar is a great project to make your backyard party-ready. For blueprints and detailed instructions on this advanced project, click on 'Download a PDF' below.   Supplies:  •    Drill Driver + Wood Screws  •    2 Sheets of 3/4" x 48" x 96"       Particle Board    •    5 planks of 8' length 2" x 4"  •    Brick Masonite (optional)  •    Wood Glue (optional)  •    Varnish (optional)

If you've got a few supplies and your Dremel Ultra-Saw, you're in luck. Just add a little elbow grease and these blueprints from Dremel weekends and you'll be the star of your Labor Day backyard bash with a custom, DIY bar.

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