| Blog series by DanMelander | updated 02-06-2016 04:50 PM | 9 parts | 9427 reads | 10 comments total |
Part 1: Planning
Working on a Craftsman side table for the living room. I started with a design I purchased from Woodsmith magazine, and redrew it in Sketchup to change a few things. The original design was narrower, had side spindles instead of slats, and a smaller drawer. I am making it out of cherry, and I’m thinking of using walnut for the top, and maybe the drawer front. The drawers will be maple with a plywood bottom. I have purchased the cherry wood, and now to get started!
Part 2: Milling the Cherry and Leg Mortises
After allowing a few days for the wood to acclimate to the shop temp and humidity, I started by milling all the major pieces to the correct dimensions and length. I had been storing the wood in my garage temporarily until I could get started on the project. Next, I worked on the mortices in the legs. I used a mortising bit in the shop mortiser. I considered using the overhead router or using the mortising jig and uncut spiral bit. These would have produce better looking mortises, b...
Part 3: Tenons and first test fit
Worked on the tenons. Here are some photos of the horizontal router I used. After some careful setup to make sure everything is square and the depth of the cut is correct, I was able to make all the tenons in a short time. After tweaking the tenons, I did the first dry fit. Starting to look like a table! Now I need to add some dados for the drawer support pieces, slats, and lower shelf.
Part 4: Start of Assembly
I added 3/8” wide by 1/4” deep dados to the upper and lower stretchers for the slats. I then glued in some 3/8’ plugs between the slats. After the glue dried, I trimmed the plugs off with the table saw, then sanded them flush with the horizontal belt sander. Could have used a router to trim the plugs flush too. This works better I think than mortise and tenons for the slats. Test fit the lower shelf to check the fit. I plan to pre-finish the shelf before a...
Part 5: Assembly
Glued up everything today. Luckily, I had a helper with the main glue up. Now on to applying the finish and start working on the drawer and top.
Part 6: Drawer part 1
Started working on the drawer today. Used a Dovetailer II jig and a palm router to do half blind dovetails. Next time, I’ll try using the shop’s Leigh dovetail jig. I think it would be more accurate. Next I need to add the back of the drawer and drawer bottom.
Part 7: Drawer part 2
It was a short day at the shop today, but was able to add the dados and rabbits to the drawer parts, and cut the drawer bottom to size. Now on to the top and finishing.
Part 8: Start of Finishing
Final sanding and applied two coats of wipe-on poly today. Pre-finished the inside of the drawer before assembly. The spalted maple drawer sides really pop with some wipe-on poly.
Part 9: Completed Table
Completed table. I finished the walnut top with 7 coats of wipe on satin poly. I sanded the top after 4 coats with a 400 grit sanding sponge and sanded the top after coat 6 with a 1200 grit sanding sponge. The final surface is super smooth. Now on to table #2, which will be narrower and deeper with a smaller drawer.
