Just finished framing your bar? Here’s how to build a durable plywood bar top with both a sub top and a finished top layer. This step-by-step guide is beginner-friendly and includes tips for fitting a Chicago bar rail.
Measure Before You Cut
Before cutting any wood, confirm the specs of the bar rail you’ll be using—our measurements are based on a specific Chicago Bar Rail. Always measure and cut as you go to ensure accuracy for your unique build.
Step 1: Build the Sub Top
Start by cutting your first sheet of ¾” plywood to form the sub top. It should overhang the front of the bar by about 8.5″ and the back by roughly 3″.
Secure it directly to the bar frame using wood glue and wood screws, placing screws every 6″ in a staggered (zig-zag) pattern.
Then cut and install a second sub top layer using the same overhang measurements.
Screw it down in the same fashion. These screws won’t be visible, but they should be flush with the plywood surface.
Step 2: Add the Primary Top Layer
Cut your finished plywood top—this will be visible, so use a higher-quality sheet. It should be 1.5 inches shorter on all sides where the bar rail will be installed, compared to the sub top.
For example, if your sub top is 18″ x 62.5″, your top layer should be 16.5″ x 61″.
Offset the seams from the lower layer for added strength. Attach the top using wood glue and screws from the bottom up to conceal hardware.
Always double-check screw length so they don’t pierce the top layer.
Final Touches
Fill any gaps or seams with wood putty, then sand smooth. Add trim or conceal screw heads with putty as needed.
Finally, attach your Chicago bar rail, sand the surface, and apply stain. Finish with a two-part epoxy for a professional, glossy finish.