Photos and Notes on the Construction of 3 Tables

TablePlan.jpg (121056 bytes) Table.jpg (21093 bytes)

Prior to purchasing the first splinter of wood, I designed the tables using Microsoft Excel, Paintbrush, and AutoCad.  Some of the designs are pictured at left.  Excel allowed me to quickly change design features and calculate wood use, Paintbrush gave me a quick look at visuals, and AutoCad allowed me to look at 3-d views.

Tab-Frames.jpg (186991 bytes)

This is the earliest photo I have of the work in progress.  I should have taken a picture of Megan's truck loaded with the wood and gone from there.  Anyway, by the time of the photo  I had already constructed the table bases using maple for the frame and Honduras mahogany for the legs.  I picked up a taper jig to get the leg tapers ripped correctly.  In the foreground is the MDF with the maple edges attached.  In the background are the table bases hanging around waiting to be attached to the MDF.

Tab-Spline1.jpg (161834 bytes) Tab-Spline2.jpg (141231 bytes)

These photos illustrate the edge band attachment detail.  Here, I've inserted a mahogany spline to attach the maple to the MDF.  Also, the maple has been rabbeted to create a ledge even with the height of the MDF, allowing for roughly 1/4 inch onlay strips to be applied to the top surface.  The spline not only held the edges to the MDF, but un-warped them a bit as well!

Tab-Garage.jpg (176282 bytes) Tab-Garage2.jpg (195731 bytes)

Tab-Mess.jpg (221603 bytes)

To give an impression of my workspace, I photographed the small garage from opposite ends.  I also included a shot of one of the tables while it was being used for tool "storage" and sawdust catcher.  Needless to say, I was constantly banging into things, bruising myself, and getting lost.

Tab-EdgeClamp2.jpg (206694 bytes) Tab-EdgeClamp.jpg (175423 bytes)

Here are shots of the first few planks of onlay being glued to the table surface.  These slats run parallel to each of the four sides of the table.  The maple has a 45 degree miter while the purple heart and ebony are joined at 90 degrees.  Clamps and weights secured the onlay to the table surface as well as outer layers.

Tab-PurpleHeart.jpg (184966 bytes) Tab-PurpleHeart2.jpg (171758 bytes)

Now it was time to attach the purple heart.  I used 8/8 (or 1 and 3/4 inch finished) width stock as seen in the photo.  That board is about 9 and 1/2 inches wide and ten feet long!  This stock was cut into approximately three foot lengths then ripped to 1/4 inch thickness.  This piece and another smaller piece provided 63 slats of 1.75"x0.25"x3.0'.  Just to be safe, I used two new saw blades to ensure clean, relatively burn-free rips. 

Tab-Sawdust.jpg (224416 bytes) Tab-Sawdust2.jpg (189396 bytes)

Tab-Sawdust3.jpg (192902 bytes)

Tab-Sawdust4a.jpg (200061 bytes)

Needless to say, all that sawing created a massive amount of sawdust.  Most of the time I was in the garage, I wore an air filter and safety gogs.  The last photo is a cross-section of the pile showing order of wood ripping.

Tab-Slats.jpg (196654 bytes)

Here the purple heart goes in.  About 21 slats are used in each table.  Barbell weights applied downward pressure to the slats.  The disk weights applied weight to a pitched structure that exerted lateral pressure to the slats, ensuring a tight joint between each slat.  Also note that some maple slats are quite severely saw-burned.  I foolishly used an old, dull blade to rip a few pieces of wood with considerable difficulty, but I was determined to use those pieces anyway.

Tab-QtrRound2.jpg (153157 bytes) Tab-QtrRound.jpg (176430 bytes)

After the top was installed, but before final finishing, I inverted each table to apply the red oak quarter round trim.  This trim covered up various gaps and screw-ups in attaching the table bases to the table tops.  Since the trim needed to be glued on two surfaces, I applied weights at an angle, providing force in two directions simultaneously.

Tab-Sander.jpg (211399 bytes) Tab-Sander2.jpg (197295 bytes) Tab-Sander3.jpg (179634 bytes)

This is a series of photos of the last table I began sanding.  The first photo shows three "raw" edges and one edge after about 10 minutes of belt sanding at 50 grit.  Last photo after an hour.

Tab-Three.jpg (202014 bytes) Tab-Three2.jpg (222646 bytes)

For the first time, I lined up all three tables.  Each is in a different stage of finishing work.  Here I wanted to see how well they lined up and/or fit together.  The results were fairly good, but putting "identical" objects side-by-side highlights the differences (read irregularities).  Well, with a little arranging, maybe I can get them all working together.  Now - on with the finishing work.

Tab-OS1.jpg (75727 bytes) Tab-OS2.jpg (124429 bytes)

Tab-OS3.jpg (55722 bytes)

Tab-OS4.jpg (87048 bytes) Tab-OS5.jpg (245252 bytes)

To better secure the corners of the edges, I inserted mahogany splines "open" to view.  These photos show the process of installing these open splines.  Color variations in the maple are due to lighting since no finish was yet applied.

Tab-FS1.jpg (215139 bytes) Tab-FS2.jpg (178491 bytes)

Here are shots of the tables after final sanding.  I did all final sanding outside to prevent dust buildup in the garage, where I planned to apply the polyurethane finish.  In the photo on the right, you can see the reflection of objects (like the white vans) on the surface of the table.  I was delighted to see this effect from unfinished wood!

Tab-Fin1.jpg (221083 bytes) Tab-Fin2a.jpg (132199 bytes) Dina_Tables.jpg (137999 bytes)

I applied the first coat of polyurethane!  Finally!  Here only the tabletops are coated.  That polyurethane really brings out the color and depth of the wood.  I had a heck of a time getting an even application since I had to keep the garage door closed to minimize dust, thereby preventing adequate light in to illuminate the workspace.  Catch-22.

Now, on to making a couch . . .