How to Build a Bar From Cardboard

Used cardboard can be transformed into an interesting bar.

Cardboard furniture is both art and furniture. This common material can be manipulated to create the design and shape of almost any type of furniture. Once properly glued together, cardboard is actually quite strong and durable. Because a bar top is likely to become wet when drinks are served, you will have to go further and add a finish to the top of the counter to protect the cardboard from moisture damage.

Things You'll Need

• Craft paper
• Pencil
• Scissors
• Cardboard
• Box cutter with extra blades
• Carpenter's glue
• Foam paint brush
• Scrap board
• Bar clamps
• Toilet paper tubes
• Drill with hole-saw blade
• Alcohol magazines
• Decoupage medium
• Polyurethane

Instructions

1. Place craft paper on the floor in the area where you want the bar. Draw the shape of the bar top on the paper so that it fits the area. Your bar top can be curved or straight. Draw a square 3 by 3 inches in size, 6 inches from the narrow end and centered in the bar top. Repeat for the second side. Draw a square the same size in the center of the length if your bar is longer than 4 foot. Each square is the location of a leg. Cut out the pattern of your bar top.

2. Draw the shape of a bar leg that is 3/4 the depth of the bar top. The top and bottom of the leg should be full 3/4 depth. The space between can have a curved shape so long as the majority of the leg remains thick. The height of the leg should be 3 inches less than the height of the bar. Standard bar height is 42 inches minus 3 inches for 39-inch legs.

3. Draw a peg emerging from the top of the leg that is centered on the leg, 2 7/8 inches wide and 6 inches tall. This peg will go through the square holes in the bar top to hold the leg and top together. Cut out the pattern of your leg. You will need to build a leg for each hole in the bar top.

4. Use your best sheets of cardboard for the bottom and top pieces of the bar top. Place one sheet of the cardboard on a cutting mat so that the corrugation is running lengthwise. Trace out your bar top pattern. Before you cut decide if you want to contour the cardboard. If you cut on a 45-degree angle you can shape the bar edge to curve by making each piece of cardboard fit the angle. Cut the shape using a new blade in a box cutting knife. Be as clean as possible with your cut.

5. Place your cut bottom piece over your next cardboard sheet. If you are cutting contour, turn the cut bottom piece with the wide part of the angle down. Trace out the pattern. Cut your second piece. Your recycled or used cardboard can be used -- just remove all tape and staples so that the cardboard lays flat when you cut it. You can use two or more pieces to achieve the length you need except for the top and bottom pieces.

6. Place your second piece over your first so that the angle matches. Clean up the edges to make the pieces fit as close as possible. The peg holes should be clean and exactly the same size. When you are happy with the second piece, turn it wide-angle-down over the next piece and trace out the pattern. Before cutting your third piece, paint carpenter's glue over the first piece and position the second piece over the first so they are perfectly aligned.

7. Place the cardboard on a table. Position a long piece of scrap lumber over the cardboard with a bar clamp on each end to hold the cardboard together while it glues. Cut your next piece. Unclamp and fit your piece cleaning up all your edges. You will quickly see how angling your knife will allow you to contour the edge. By changing the angle, the contour becomes more vertical. A rounded edge should bring you vertical when your glued top is 1 1/2 inches thick, then your contour should angle in the opposite direction until you reach the top layer. Continue this process until you fit your nice top cardboard in place. Allow the entire stack to dry for 24 hours.

8. Repeat the construction process for each leg. After the glue has dried for 24 hours, assemble your bar by sliding the pegs through the bottom of each peg hole. The peg should emerge through the top. Locate the center of the peg that is above the top and mark each leg where the peg comes through the counter. Use a hole saw the size of a toilet paper cardboard tube and drill through the cardboard legs just above this line.

9. Cut cardboard the height of your cardboard tube. Make cuts along the corrugation on one side of the cardboard. Roll the cardboard to fit tight inside the tube. Remove the cardboard and paint the inside of the tube with glue. Insert the rolled cardboard. Assemble your table again and slide the tubes through the leg holes.

10. Cut images out of a wine, drinks, beer or alcohol-related magazine. Paint the top of the bar with decoupage medium and position your images in the medium. Smooth out the paper. Cover the entire top with 2 to 3 layers of images. Allow each layer to dry for 4 hours. Finish the bar top and legs with coats of polyurethane. Apply several coats for a nice finish.

Tips & Warnings

• Any kind of images can be used to cover the top of the cardboard for a nice counter finish.

References

• Earth 911: Reuse Challenge: The Cardboard Chair
• Re-Nest: How to Decoupage Furniture and Other Items