Man Cave Wood Pallet Bar {Free DIY Plans}

So one of my very convincing friends asked me if I would build him a pallet bar for his theater room.  I normally say no to these requests because I hate lugging my tools all over and I am always so afraid it won’t turn out the way I envision it in my head and that it will fall apart or something terrible. {Yah a real positive thinker I am!) I found some reclaimed pallet type wood for free from this older man named Fred (isn’t that the perfect name for a pallet building dude?).  All in all, this cost about $135 for an almost 10’’ foot bar for a man cave!

reclaimed wood bar

 

Supplies:

(all wood from Lowes)

(9) 2” x 4” 10’

1” x 6” x 10’ (4)

1” x 4” x 10’ (2)

1” x 4” x 8’ (1)

3” angle braces (2)

2 1/2” wood screws

Kreg Jig

2 1/2” Kreg Screws

measuring tape

table saw (for ripping boards)

chop saw

Air Nailer (I use a Ryobi Airstrike) with 1 1/2” nails

cordless drill

Rockwell Orbital Sander

stain and a top coat of your choice (I used Minwax Dark Walnut and Semi-Gloss Polyurethane)

wood glue

clamps

 

The overall size of this bar is 39 1/4” by 9’ 8”

To build the side of your base frame you will want to cut (4) 2×4’s @ 16” and (4) 2×4’s @ 38 1/2”.  Drill 2 pocketholes into each end of the 16” 2×4’s and use Kreg Screws to attach it to your 38 1/2” 2×4 boards.  Make sure your 38 1/2” boards on standing on its side when you drill them in.

man cave bar

Next cut (3) 2×4’s to the length you want your bar to be.  I used (3) 112” boards which made my overall bar, once done, about 9’ 8” (including bar top).  I used regular wood screws to nail those into the inside of the side frame, two boards at the top (front and back of the bar) and one at the bottom.

Next, I cut 10 more 2×4’s @ 38 1/2” and screwed these into the long 2”x4’s I just framed.  I spaced them evenly apart.  This will be what the pallet wood will be nailed to so you want to make sure you have enough supports to have somewhere for each board to attach too.  You can use more or less depending on how long your reclaimed wood is.

building a pallet bar

I ended up doing this after I attached some pallet boards to the front – but you will also have to cut 2 x 4 boards on the inside of the frame nailed into the front 2×4’s.  I cut mine at 31 1/2”. These boards will need to fit inside your top and bottom 112” boards.  You can see the stacked 2×4’s in the picture below.  I just used my nail gun to attach them to the other screwed in 2×4’s.

bar for man cave

reclaimed wood bar

Also, grab some angle braces and attach it to your base.  Then screw those into the subfloor to give sufficient stability to your oversized bar.  If you don’t want to do this then you will have to make your sides way wider to accommodate the size of this bar.  Don’t worry about seeing the angle braces they will be covered with pallet wood.  You could also attach one side to wall studs for more stability if it touches a side wall (see angle brace in picture below).

pallet bar

To add stability to the tabletop add 7 or so 2×4”s cut @ 16”. Drill 2 pocket holes into each end and secure them to the top 112” boards with Kreg Jig screws.

man cave pallet bar

Now using pallet boards and a nail gun attach pallet boards to the front and side of your base making sure a nail goes into all those 2 x 4 supports. All my pallet boards ran horizontally except for the inside corner edge piece.  You want to be careful in the corners that you don’t have any cut edges showing.  You want to maintain the worn edge showing (see picture below to see what I mean).  You might have to rip that vertical board to fit just so.

building a reclaimed wood bar

You will also have to add additional support to the side frame inside in order to have something to attach your pallet boards too.  See picture below.

reclaimed wood pallet bar

The only part that drove me crazy was having to build around all the cords to the sound system/TV.  I just left that open and we ended up finding a small table to slide underneath the bar to have all that stuff sit on. It isn’t the best solution but something that works for now. I also added pallet wood to the inside top 2×4.

reclaimed wood bar

I thought long and hard about all the options for the bar top.  In the end, in order to keep the cost low on this build, I used (4) 1×6 pieces of pine wood and drilled pocketholes on the backside and glued and clamped them together.  Then I flipped it over and sanded the snot out of it so you could barely see the seams. I highly recommend an orbital sander for this, a regular palm sander would take days to make smooth. It was messy and took forever but is absolutely stunning in the end!

I forgot to take a picture of the pocketholes but it looks similar to this without the side pieces and only 4 boards…

kreg jig table top

reclaimed wood bartop

Next, I added 1” x 4” pieces and framed out the bar top so it looked thicker.  I air nailed them into the bar top and mitered the corners and dry fit it to the base.  I did not add a trim piece to the side closest to the wall I just butt the top right edge of the bar top to the wall edge.

wood bar

I used Minwax Dark Walnut for the top followed by about 5 coats of Minwax Semi-Gloss Polyurethane.  I made sure to sand with 400 grit between coats to get a nice smooth finish.  I raised it up during this process so I didn’t have to tape it off.

Man Cave Wood Pallet Bar

All my sanding paid off.  You can barely even tell I joined the top together with pocketholes.  To attach the bar top to the base I used long screws on the inside.  If you don’t mind nail holes you can also drive air nails through the top or trim into the base.  Since it is rustic already I didn’t patch up any holes.

pallet wood bar

building a basement bar

My friend was so excited to have it in his man cave.  I also took 180 grit sandpaper and went over all the pallet wood after it was build just to make sure his twin toddlers wouldn’t get any slivers.

This stamp on the wood is my favorite part of the bar…

wood bartop

It is perfect for extra seats and an eating area for the big game…

reclaimed wood bar

My friend ended up purchasing 3 leather like barstools.  He could have fit 4 in the space tightly.  But men need room I guess (you know the rule of sitting a chair away from each other in a movie theater??)  Obviously if he didn’t have the sound stuff under there he could fit 4-5 stools.

wood pallet bar

TOUCHDOWN!!!! Man cave perfection.  I would have more decor on the walls but hey…to each his own ;-P

pallet bar

For more building plans click on the pictures below to check out…

DIY cart plan with 2x4

Farmhouse Pallet Bed with Rolling Trundle Bed

DIY laundry rolling shelf

 

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