Bar top - materials

[jozimmer]

My bar top will have tile, so I'm using hardibacker board. My question is if I should use heavy-duty particle board (1/2'', or 3/4'') under the cement board, or if I should use hardwood plywood or something else? Needs to attach to a 2X4 frame.

Bigger Question: What are people using for the top bar lip? My bar is over 9 feet and most bar top lips I've seen come in 8 ft. max. Is there something else others have used? No one really talks about the details of the bar, like the bar lip.

[Slev]

I would not recommend using particle board, a cheap piece of plywood will suit you fine. Just attached the 1/4" hardibacker to the plywood and proceed with tiling.

I have a 10' bar and did not want to have a seam in the bar rail. Purchasing bar rail on line limits you to 8' sections, as that is the longest they can ship. What I did was found a local mill (not so local, it was a 45 minute drive but well worth it) where I was able to purchase up to 20' lengths of bar rail and the cost per foot was $2 cheaper than any online products I found. If I remember correctly, I paid $12.50 per linear foot (red oak) compared to the $14-15 range found online. Do a search for local wood mills, they most likely have 2 or 3 different types of bar rail, in many wood types. Also, it is much easier to install the bar rail BEFORE laying any hardibacker or tiles. My bar (see below) I installed the rail first, then the tile, then I added an epoxy coating that is SWEET! Hardens like glass.

http://i696.photobucket.com/albums/vv328/Slev09/CIMG3378.jpg

for reference, see the rest of the pics here: http://perfectmancave.com/forum/showthread.php?t=15094&page=3

[jozimmer]

Thanks for the info. on the particle board and bar rail. I'm just outside of Nashville so I'm guessing I can find a mill place somewhere nearby. I wouldn't have thought about going there, so glad you said something.

[jozimmer]

Ended up splurging and buying 1/2'' birch hardwood. The problem with other plywood was over the 8 ft. it wasn't straight at all....and had more a U-shape to it. Hardwood board is nice and flat.

Put Permabase on top of it due to the screw length I needed. 1 inch. total thickness of my bar, but the Hardibacker screws that I found were 1 1/4'' total length which just wouldn't work. Durock/Wonderboard/Permabase screws were 2 1/4'' which work great. Permabase isn't bad, just doesn't snap all the way through after it's scored. Fiberglass mesh REALLY holds it together though: one strand kept me from pulling a cut piece away.

Found a local mill place in Nashville that cut a bar rail special for me. It was their design but I didn't care. Ordered and paid for 12 ft., got 14-8''.

[Quads]

Nicely done.
Pics?!!?!?