Copper & Wood Bar Cart

Directions

1. Measure and cut your 1×3 boards into the following pieces: (4) Short Frames @ 16 ½”(4) and Long Frames @ 29″.
   
2. Measure and cut your dowels into four 36″ tall pieces.
   
3. Measure and cut your plywood boxes into two pieces at 16 ½ x 32″.
   
4. Once your pieces are cut, use a spindle sander to add a curve to the end of your 1×3 pieces. This helps them hug the dowels and is a totally optional step.
   
5. To help the dowels lay flush to the plywood, use a jig saw to cut the hard corners away from the plywood panels.
   
6. Next, drill pocket holes into the bottom of your plywood panels.
   
7. Once the plywood is finished being prepped, drill pocket holes into the ends of your 1×3 boards. (This is what you will use to attach to your dowels.)
   
8. Next, begin your shelf assembly by attaching the plywood panels to your 1×3 boards using wood glue and 1″ pocket holes screws. You can use a spacer to attach the plywood to the middle of the frame pieces and allow some space both under and over the shelf.
   
9. Cut your copper pipes into the following sizes (these measurements include the room required for the coupling I used): (4) Long Rods @ 28″ and (4) Short Rods @ 15 ½”. You can add coupling to the ends of the copper piping to help it remain stick straight – it also adds a fun decorative element as well.
   
10. Next, clean the outside of the copper pipes and the inside of the copper coupling to prep it for soldering.
    
11. Once clean, add flux to the inside of the copper coupling and outside of the copper pipe.
    
12. Next attach the coupling to the end of the pipe and begin to heat using the Bernzomatic TS4000.
    
13. After a few minutes, remove the direct flame and touch the connection between the pipe and the coupling with your soldering wire. It should begin to melt onto the pipe. Keep a wet rag around to fix any dripping. Continue this process for all 8 rods and all 16 couplings.
    
14. Once the rods have cooled, clean up the connections using a metal file.
    
15. Next, buff the copper pipes using 320 grit sandpaper and then follow with an abrasive sponge or steel wool. (I picked up this trick from fellow Torch Bearer, Modern Builds.)
    
16. Begin attaching the remaining pieces of the bar cart together. First, attach the legs to the bottom shelf using wood glue and 1 ¼” wood screws.
    
17. Once your legs are in place, use a ¾” Forstner bit to create grooves for the copper pipes to sit. If you prefer, create a quick jig to keep your holes aligned, but this is optional.
    
    
18. Next, use epoxy and clamps to connect the copper pipes on the bottom shelf first.
    
19. Once the bottom shelf has been put into place, continue the same method up top.
    
20. After the piece has dried, remove the clamps and give it a good sanding.
    
21. Next, stain and seal the cart.
    
22. Optional: while the cart dries, spray your wheels copper to match the piping.
    
23. Once the wheels have dried, drill holes in the bottom of the dowels and attach the wheels.
    
24. Serve up a drink and celebrate!