Step 5 – Assemble the bar top
Glue up four 1×6 boards (E). Trim the ends of the glue up to a final length of 48 in. with a circular saw and straight edge. Cut a 3/4-in. wide x 3/4-in. deep. groove into the center of the 2×2 boards with the table saw. Cut the 2×2 sides (G) and front (F) to length on the miter saw. Spread glue into the grooves of the 2×2 parts and set them in place. Secure the front and sides with 1-1/4 in. brad nails.
Step 6 – Glue up and notch the shelf
Glue up three 1×6 boards (J). Trim the ends of the glue up to a final length of 39-3/4 in. with a circular saw and straight edge. Set the shelf in place and mark the notch locations. The notches will need to go around the hinges, side edging (C) and hinge mounts (K). Clamp the shelf to the worksurface and cut out the notches with a jigsaw.
Step 7- Fasten the alignment boards in place
Set the bar wall upright and center the bar top on the bar wall, ensuring that the side panels are at 90-degrees. Mark where the side panels (inside and outside) hit the bottom of the bar top. Glue the 1×2 alignment boards (H) to the bottom of the bar top and fasten with 1-1/4 in. brad nails.
Step 8 – Add hardware
Center the chest handle, 4 in. down from the top edge of the backside of the front panel. Drill pilot holes and fasten the chest handle with the included screws. With the bar top on the bar wall, set the 2 in. barrel bolts on the interior alignment boards (H) and mark where the bolt hits the side panel edging. Drill a 5/16-in. diameter hole at the mark. Set the barrel bolts in place, drill pilot holes and fasten with the included screws. Measure 20 in. down on the edge of both side panels. Drill pilot holes and screw in both sides of the hook-and-eye latch.