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Asssembly / Outfeed Table

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Blog series by Freakazoid updated 11-12-2015 02:18 PM 10 parts 13736 reads 2 comments total

Part 1: Starting from the ground up

08-16-2015 08:00 PM by Freakazoid | 0 comments »

This is my first blog ever, so there are some boring up front details I have to get out of the way. I have been in my house for a little over 8 years. I was fortunate that the property came with two garages – one attached to the house and the other detached from the house. Both are two car garages, and the detached building was immediately claimed as my shop space. My shop area went through several iterations over the course of the next six years, mostly because I did not have...

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Part 2: Building the frames

08-16-2015 09:31 PM by Freakazoid | 0 comments »

I did not want to use the 5 foot by 5 foot dimension of the table that I referenced in the last entry. I knew that I wanted something around 5 foot by 10 foot, but recognized that I did not want to build two tables, they would never come out exactly the same. I did some SketchUp work to try out various ideas. I came up with the idea to merge two tables into one: I do not own a bandsaw. so I had to figure out a way to cut the 4×4 legs at an angle to merge with the 2×12 beam...

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Part 3: Joining the Frames

08-20-2015 09:33 PM by Freakazoid | 1 comment »

The first two parts were pretty boring – Some background info was part I, and part II was all about building some over-complicated sawhorses with 6 legs. Hopefully this is a little more interesting. The original plan did not tie the two sawhorses together very well, it used a system of bolted together angle iron to create a suspended drawer support. This did not appeal to me. I liked the idea of the drawers, but not the way shown. I set to messing around with SketchUp again to fi...

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Part 4: Drawer Runners

08-21-2015 11:19 PM by Freakazoid | 0 comments »

I have seen numerous ways to support a drawer. In this case, I knew that I would have to make my own. The drawer runners for the lower drawers (between the legs) would need to be around 5 feet long, and the runners for the core of the table would have to be 9 feet long. I was concerned about using hardwood since I would not be able to wax them once the table was built, so I did some googling around and starting looking at HDPE for slides. Then the idea became more clear – I decide...

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Part 5: Crazy Long Drawer

08-29-2015 09:51 PM by Freakazoid | 1 comment »

The core of the table is 9 feet long, with a pair of openings on each end for two ~18 inch wide drawers. The drawers are made out of maple, which I knew would wear well on the drawer runners. I also knew I wanted dovetailed joints because these drawers would end up being pretty heavy. I marked out the tails first after reading much debate about pins first versus tails first. Tails makes sense to me, so I marked them out, cut the rough dimensions out on the tablesaw, and cleaned it up wit...

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Part 6: Adding a few accessories

09-28-2015 11:38 AM by Freakazoid | 0 comments »

I decided to add some storage accessories before I moved on to the second drawer. Mostly because a table this size displaces a lot of stuff and I really wanted to straighten up the shop a bit. I had originally wanted to build a shallow cabinet for the ends (like the ones in Woodworking for Mere Mortals), but I decided that would not be practical, so I built a cleat board for one end to see how I liked it. The purpose of this board is to hang clamps. I have seen several clamp sto...

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Part 7: Major mistake = major design change

11-02-2015 11:46 AM by Freakazoid | 0 comments »

The framework had been built for a while and I had added a few important things. Things like two layers of plywood for the top, trimmed out with locally sawn maple, a couple of drawers, some clamp caddies, etc. It was starting to come together. Then a few things popped up that I had not anticipated. First, I noticed that when I screwed the trim to the plywood top that the plywood had swelled up around the screw locations despite predrilling. Now I had humps all along th...

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Part 8: Building a better frame - workbench style

11-02-2015 02:55 PM by Freakazoid | 0 comments »

I finally gave up on the original design for the table’s frame. It turned out wobbly, and because of the A frame style of a sawhorse, I was constantly tripping over the legs since they extended out a bit further than the table top. That and I really did not like how it looked. So I went on to start rebuilding. Here is what I am going to build: I went the Schwarz route – buy wood that is cheap and readily available, and bought a bunch of Douglas Fir from the Borg. I fol...

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Part 9: More frame work

11-07-2015 09:30 PM by Freakazoid | 0 comments »

The rails and stretchers were put together in similar fashion to the legs. The dimensions of the rails and stretchers were originally intended to be 3 inches thick by 4 inches wide and cut to a yet to be determined length. For some reason, the 3×4 dimension bothered me, it just did not look right. It took a little bit of thinking about it, but I decided to pull up a Golden Ratio calculator and found out that for a 4 inch width, the thickness would need to be just under 2.5 inches. To...

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Part 10: Leg work

11-12-2015 02:18 PM by Freakazoid | 0 comments »

I am finally ready to put together the leg assemblies. Test fitting went well, some minor trimming of the tenons with a rabbetting block plane did the trick. Everything is going to be drawbored. I have tried this in the past, but on a much smaller scale. One of the things that I previously had difficulty with was getting the peg past the second offset, even though I had whittled the end of the peg to a much smaller diameter. I thought long and hard about it, and decided to shar...

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