DIY Copper & Wood Bar Cart

 

Steps

  1. Measure and cut your 1×3 boards into the following pieces: (4) Short Frames @ 16 ½”(4) and Long Frames @ 29″.
    Miter saw
  2. Measure and cut your dowels into four 36″ tall pieces.
    Wooden rods
  3. Measure and cut your plywood boxes into two pieces at 16 ½ x 32″.
    Tape measure
  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.
    Spindle sander
  5. To help the dowels lay flush to the plywood, use a jig saw to cut the hard corners away from the plywood panels.
    Jig saw
  6. Next, drill pocket holes into the bottom of your plywood panels.
    Pocket holes
  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.)
    Pocket hole tool
  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.
    Assembly with wood screws
  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.
    Pipe cutter
  10. Next, clean the outside of the copper pipes and the inside of the copper coupling to prep it for soldering.
    Sanding copper pipe
  11. Once clean, add flux to the inside of the copper coupling and outside of the copper pipe.
    Flux
  12. Next attach the coupling to the end of the pipe and begin to heat using the Bernzomatic TS4000.
    Heating copper pipe with 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.
    Soldering
  14. Once the rods have cooled, clean up the connections using a metal file.
    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.)
    Buffing copper pipes
  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.
    Wood glue
  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.
    Forstner bit
    Drilled dowels
  18. Next, use epoxy and clamps to connect the copper pipes on the bottom shelf first.
    Epoxy
  19. Once the bottom shelf has been put into place, continue the same method up top.
    Attaching shelf
  20. After the piece has dried, remove the clamps and give it a good sanding.
    Sanding
  21. Next, stain and seal the cart.
    Wood stain
  22. Optional: while the cart dries, spray your wheels copper to match the piping.
    Casters
  23. Once the wheels have dried, drill holes in the bottom of the dowels and attach the wheels.
    Drill dowels
  24. Serve up a drink and celebrate!
    Complete cart

What You'll Need


TS4000
TS4000

High Heat Torch for Fast Work Times

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TX9
TX9

14.1 oz. Propane Hand Torch Cylinder

Learn More

Tools

  • Miter Saw
  • Table Saw
  • Pocket Hole Jig
  • Jig SawSolder & Flux
  • Pipe Cutter
  • Pipe Cleaning Tool
  • ¾” Forstner Bit
  • 320 Grit Sandpaper
  • Metal File
  • Steel Wool/Abrasive Sponge
  • Spindle Sander (optional)
  • Wood Clamps
  • Safety Goggles
  • Safety Gloves

Materials

  • (1) ½ Sheet of ½” Plywood
  • (4) 48″ Tall 1¼” Dowels
  • (4) 1 x 3 x 6′ Boards
  • (3) 5′ Tall ½” Copper Pipes
  • (16) ½” Copper Couplings
  • (4) Ball Stem Castors
  • 1 ¼” Pocket Hole Screws
  • 1″ Pocket Hole Screws
  • Copper Spray Paint
  • Danish Oil (Dark Walnut)
  • Fast Setting Epoxy
  • Painter’s Tape
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