DIY Network

Building a Kitchen Bar Add storage and counter space — without a wall. From "Wasted Spaces" episode DWSP-306

Define the space — without closing it off.

Jack and Jody opened up a lot of space when they tore down the wall between their kitchen and dining room – but they also lost a lot of counter space and storage. Instead of one big, flowing area, it's one big, awkward area with no definition of where the kitchen ends and the dining room begins.

Host Karl Champley helps this frustrated couple stake out their kitchen territory, starting with a new base cabinet that will come out from the existing wall to add counter space, storage and even a handy spot for the kids to have breakfast. He later installs the bar and builds a tall custom cupboard perfect for storing everything from brooms to small gadgets.

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Building a Kitchen Bar

Tools: carpenter’s pencil safety glasses measuring tape chop saw circular saw finish nailer nail gun screw gun orbital sander level paint trays, brushes, rollers

Materials: birch plywood 2" x 8" pine lumber wood glue nails finish nails screws trim strips for the cabinet newel post tongue-and-groove pine panels primer and paint trim

	Figure A
	Figure B
	Figure C
	The new bar is ready to install.

• Sketch out a plan. This kitchen bar will replace part of the wall Jack and Jody removed between their kitchen and dining room, adding much-needed storage and counter space (figure A). The height will be 34-1/2" to bring the new countertop in line with the existing counter. The unit will be 4'9" long, with the kitchen side open for easy access to the items stored below. The main body of the bar will be 3/4" birch plywood, with 2" x 8" pine used for the shelf brackets.

• Cut the plywood. Use a table saw or circular saw to cut the plywood and pine to the dimensions from the plan.

  Safety Alert: Always wear safety glasses and use caution when working with a power saw or any power tool.

• Build the box. Use wood glue and a finish nailer to assemble the open box that makes up the main body of the cabinet.

• Assemble the shelves. Use wood glue and nails to attach the brackets to the shelf (figure B). Position the shelf inside the box, make sure it's level and attach the shelf and brackets using wood glue and nails. With the shelf in place, drive screws through the back of the plywood box into the brackets for extra support.

• Add trim. Use wood glue and a finish nailer to add rim strips to the cabinet (figure C).

• Attach the newel post. Dry-fit the newel post into position at the corner of the cabinet. Attach the newel post using wood glue and nails. Once the post is secured, drive screws down through the top of the cabinet into the top of the post to reinforce the joint.

• Dress up the back. Use glue and a finish nailer to attach tongue-and-groove pine panels to the back of the cabinet. Drive the nails through the edge of the panels at an angle. This way, the next panel will hide the nail heads.

• Sand and finish. Use an orbital sander to sand the entire piece, then prime and paint as desired.

The bar's almost done; check out how Karl and the crew install it in the kitchen.