Barnsley Reproduction Build #17: Top is Flattened

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Blog entry by stevo_wis posted 03-04-2015 02:49 AM 1460 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 16: Making the Table Top Part 17 of Barnsley Reproduction Build series Part 18: Back to The Stretcher »

I was able to take my top to the night class I have been attending. They have a beautiful wide belt sander. It has two belts and it was set up with 120 and 150 grits.
Before sanding, i just hit the high spots with my Bedrock 606.
The machine is very accurate to the point where the second belt is set just a few thousands deeper than the first belt so that it grinds out the grooves from the rougher grit. It only takes about 8 thousands of an inch per pass and it took about five passes on each side to come up with a perfectly flat and silky finish. It did take three of us to feed, catch and flip the top.

I had thought about using a table saw to rip and cut the top to length, but it was quite difficult to handle the top. The school also has a Festool track saw so I used that to rip the table to width, then cut to length, and finally cut off the corners of the top. I had never used a Festool before and it was dead on accurate and very easy to use. The saw and track are are great tools and if they would cut the price by 2/3 I would own one.

Finally I wrapped cardboard and cutoffs on all four edges and shrink wrapped the entire table. Even though I can’t lift the table alone, I can lift one end and using some rollers I was able to get it into my truck, haul it home, and then reverse the process to get it into my shop. The top still needs butterfly keys cut into the table and chip carving done on the edges. I am going to have to put that off for a while and get back to finishing the stretcher.

-- Stevo

6 comments so far

View bunkymarie's profile


4 posts in 2618 days

#1 posted 03-04-2015 03:05 AM

That looks beautiful! Must be heavy!

View lightweightladylefty's profile


3667 posts in 5051 days

#2 posted 03-04-2015 03:49 AM


I’ve never had the pleasure of working with any Festool equipment, but I do agree with you about the price. As a hobbyist, I certainly can’t legitimize its cost.

I’m glad you were able to take advantage of the school’s equipment (and a couple of helpers) to get that top sanded.


-- Voltaire: “Those Who Can Make You Believe Absurdities, Can Make You Commit Atrocities” There are 112 genders (not including male and female)

View stefang's profile


17040 posts in 4673 days

#3 posted 03-04-2015 03:33 PM

The Festool is fantastic from all reports. I think it would be a great investment for a professional woodworker. I so seldom even use a circle saw that I sure wouldn’t consider buying one. I’m looking forward to seeing the carving you will be doing on the table top. It is sure to be a classic that will be around for a long time to come.

-- Mike, an American living in Norway.

View stevo_wis's profile


128 posts in 4366 days

#4 posted 03-04-2015 04:12 PM

The carving is just chip carving like what I did on the legs, plus the butterfly keys will also add a nice touch I think.

-- Stevo

View greenwoodbodger's profile


2 posts in 2758 days

#5 posted 03-05-2015 01:58 AM

It’s’s cheating using a wide belt sander, the bedrock would have done a better job.

View stevo_wis's profile


128 posts in 4366 days

#6 posted 03-05-2015 02:19 PM

I can see there is a heckler in the bunch. It did work well to hit it with the 606. If I only had a bedrock 602 then I would really be in business. In truth the belt sander was too good to resist.

-- Stevo

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