End Table project

bandit571 said:

End Table Project: Start up

Have a stack of White Oak planks to molest. Boss said she wants a new end table.

Bottom is enclosed

Has a door
Top squared off

So, with that set points and a couple trips with the tape measure, it is off to the Dungeon shop:
Took along ONE plank for this trip. Me and stairs are not on the best of speaking terms right now, so minimum loads going down the steps works best.

Plank was 9" wide, by 63" long, by 7/8" thick. Figured I could get the top out of it. Crosscut it in half, about 31" or so. Part of the one half had a line of very bad looking knots. Rip a 2" wide strip to get rid of that sort of trouble. Set up each piece in the vise. had some jointing to do to make a better glue joint..

22" long jointer plane. Once two edges were straight and square, got out a few clamps..

Two under, one over. Just until a bead shows up..

And let it set for awhile. Went back upstairs and selected a second plank. Laid it on the glue up. Found a center point. Clamped the new plank in place ON the top clamp. Circular saw ( 1950s model Skil) to make a cut.

Bandsaw still can not make a decent STRAIGHT line to save it's rearend..
So, made a couple layout lines 3" in from each edge. Clamped a piece to the table of the bandsaw. Made sure both cuts would miss the table's edge. And made a few cuts. Not perfectly straight, but better than the bandsaw does. Wound up with 4

Code:

 3" wide, and 2

2/12" wide.

The idea here is to build corner posts.

Something like this. Now, since the edges needed a little work, and the parts needed to match each other….makes it easier to do some joinery..
jack planes to plane to lines, running two boards at a time..

Once I had the 4 wider ones where they matched each other, then the skinnier two wer planed down, made a bit of a mess on the floor(again)

Ah, but I wasn't quite done with these parts…yet. I dug up a pattern, traced it onto the "bottom" end. Bandsaw can cut curvy lines

A bit of sanding to remove saw marks, traced it out on the skinnier part, and ran that through the bandsaw

So, this is ONE corner post's foot. Three more to mill up. Sides will be a Frame & Panel sort of thing.
Will be puttering along today, rest of the feet to do. Then maybe start on the rest of the frame's parts.

Fun is just beginning in The Smokey Dungeon Shop…Stay tuned

Click to expand...

bandit571 said:

End Table Project: Start up

Have a stack of White Oak planks to molest. Boss said she wants a new end table.

Bottom is enclosed

Has a door
Top squared off

So, with that set points and a couple trips with the tape measure, it is off to the Dungeon shop:
Took along ONE plank for this trip. Me and stairs are not on the best of speaking terms right now, so minimum loads going down the steps works best.

Plank was 9" wide, by 63" long, by 7/8" thick. Figured I could get the top out of it. Crosscut it in half, about 31" or so. Part of the one half had a line of very bad looking knots. Rip a 2" wide strip to get rid of that sort of trouble. Set up each piece in the vise. had some jointing to do to make a better glue joint..

22" long jointer plane. Once two edges were straight and square, got out a few clamps..

Two under, one over. Just until a bead shows up..

And let it set for awhile. Went back upstairs and selected a second plank. Laid it on the glue up. Found a center point. Clamped the new plank in place ON the top clamp. Circular saw ( 1950s model Skil) to make a cut.

Bandsaw still can not make a decent STRAIGHT line to save it's rearend..
So, made a couple layout lines 3" in from each edge. Clamped a piece to the table of the bandsaw. Made sure both cuts would miss the table's edge. And made a few cuts. Not perfectly straight, but better than the bandsaw does. Wound up with 4

Code:

 3" wide, and 2

2/12" wide.

The idea here is to build corner posts.

Something like this. Now, since the edges needed a little work, and the parts needed to match each other….makes it easier to do some joinery..
jack planes to plane to lines, running two boards at a time..

Once I had the 4 wider ones where they matched each other, then the skinnier two wer planed down, made a bit of a mess on the floor(again)

Ah, but I wasn't quite done with these parts…yet. I dug up a pattern, traced it onto the "bottom" end. Bandsaw can cut curvy lines

A bit of sanding to remove saw marks, traced it out on the skinnier part, and ran that through the bandsaw

So, this is ONE corner post's foot. Three more to mill up. Sides will be a Frame & Panel sort of thing.
Will be puttering along today, rest of the feet to do. Then maybe start on the rest of the frame's parts.

Fun is just beginning in The Smokey Dungeon Shop…Stay tuned

Click to expand...

bandit571 said:

Mortise and tenon time

Well, at least enough to put ONE frame together. Had the five parts for the one side laid out. "Plan" was to mill a few tenons, then chop a few mortises to match. Got a few tenons done, before the insurance guys showed up. Spent maybe an hour talking things over with them, and the landlord.

Anyway, about them tenons..

Needed a few tools. laid out 1" wide tenons. Simple to do, as the blade on the square is 1" wide. Marked all the way around the ends. Handsaw to cut around 1/4" deep, or so. The rails do have at least one groove milled into them, so depth of cut matched that. Once one side was cut up. flipped the board over..

And cut the over side. I make one saw cut. Then a wide chisel to pop off the waste.. then pare the part flat

Top and bottomrails need a little extra done. Called a Haunch Tenon. The step there is to fill the groove in the stiles.

The center rail didn't need that fancy stuff. Raised panels will slide into the grooves. Got three rails done, and stacked the boards up for a bit

As I needed to clear off the benchtop. have a jig of sorts, to work on chopping a mortise

I screw the jig to the benchtop, right over a leg. A "C" clamp to hold the part in place.
I used the tenons to mark out where they will need a mortise to be. Just a couple lines across is all I need. Got out the chisels and a mallet, and chopped down…down…..down ( are we there yet?) until the combo square sits nicely. have it set at 1". When the mortise is deep enough the blade on the square doesn't touch the bottom….I can move things around and do the next one.

After all three are chopped out, I can do a fit up of sorts. They will need a bit of fine tuning….

Once they sat square, I could lay the other stile in place, and mark where the mortises needed to go. Then a lot more chopping to do. Finally clamped the whole mess together, using the jig to steady things

Close, but will take a bit more fitting up. Once that is done…I get to do the other side the same way. Then, maybe….I can do the back of the end table. Front will be just a door.

I also got some layout on the rear frame and panel. needed to know how wide it will be, based on the width of the top, how much overhang I will use, and how the stiles will add up. leaves about 10-1/2" or so for the three rails. Counting their 1" tenons. Hey, I even wrote a couple things down ON paper today…..

Once I get the frames all nice and "happy, happy" I can raise a few panels. maybe this time next week….we might try some assembly! Til then, stay tuned…

Click to expand...

bandit571 said:

Mortise and tenon time

Well, at least enough to put ONE frame together. Had the five parts for the one side laid out. "Plan" was to mill a few tenons, then chop a few mortises to match. Got a few tenons done, before the insurance guys showed up. Spent maybe an hour talking things over with them, and the landlord.

Anyway, about them tenons..

Needed a few tools. laid out 1" wide tenons. Simple to do, as the blade on the square is 1" wide. Marked all the way around the ends. Handsaw to cut around 1/4" deep, or so. The rails do have at least one groove milled into them, so depth of cut matched that. Once one side was cut up. flipped the board over..

And cut the over side. I make one saw cut. Then a wide chisel to pop off the waste.. then pare the part flat

Top and bottomrails need a little extra done. Called a Haunch Tenon. The step there is to fill the groove in the stiles.

The center rail didn't need that fancy stuff. Raised panels will slide into the grooves. Got three rails done, and stacked the boards up for a bit

As I needed to clear off the benchtop. have a jig of sorts, to work on chopping a mortise

I screw the jig to the benchtop, right over a leg. A "C" clamp to hold the part in place.
I used the tenons to mark out where they will need a mortise to be. Just a couple lines across is all I need. Got out the chisels and a mallet, and chopped down…down…..down ( are we there yet?) until the combo square sits nicely. have it set at 1". When the mortise is deep enough the blade on the square doesn't touch the bottom….I can move things around and do the next one.

After all three are chopped out, I can do a fit up of sorts. They will need a bit of fine tuning….

Once they sat square, I could lay the other stile in place, and mark where the mortises needed to go. Then a lot more chopping to do. Finally clamped the whole mess together, using the jig to steady things

Close, but will take a bit more fitting up. Once that is done…I get to do the other side the same way. Then, maybe….I can do the back of the end table. Front will be just a door.

I also got some layout on the rear frame and panel. needed to know how wide it will be, based on the width of the top, how much overhang I will use, and how the stiles will add up. leaves about 10-1/2" or so for the three rails. Counting their 1" tenons. Hey, I even wrote a couple things down ON paper today…..

Once I get the frames all nice and "happy, happy" I can raise a few panels. maybe this time next week….we might try some assembly! Til then, stay tuned…

Click to expand...

bandit571 said:

Mortise and tenon time

Well, at least enough to put ONE frame together. Had the five parts for the one side laid out. "Plan" was to mill a few tenons, then chop a few mortises to match. Got a few tenons done, before the insurance guys showed up. Spent maybe an hour talking things over with them, and the landlord.

Anyway, about them tenons..

Needed a few tools. laid out 1" wide tenons. Simple to do, as the blade on the square is 1" wide. Marked all the way around the ends. Handsaw to cut around 1/4" deep, or so. The rails do have at least one groove milled into them, so depth of cut matched that. Once one side was cut up. flipped the board over..

And cut the over side. I make one saw cut. Then a wide chisel to pop off the waste.. then pare the part flat

Top and bottomrails need a little extra done. Called a Haunch Tenon. The step there is to fill the groove in the stiles.

The center rail didn't need that fancy stuff. Raised panels will slide into the grooves. Got three rails done, and stacked the boards up for a bit

As I needed to clear off the benchtop. have a jig of sorts, to work on chopping a mortise

I screw the jig to the benchtop, right over a leg. A "C" clamp to hold the part in place.
I used the tenons to mark out where they will need a mortise to be. Just a couple lines across is all I need. Got out the chisels and a mallet, and chopped down…down…..down ( are we there yet?) until the combo square sits nicely. have it set at 1". When the mortise is deep enough the blade on the square doesn't touch the bottom….I can move things around and do the next one.

After all three are chopped out, I can do a fit up of sorts. They will need a bit of fine tuning….

Once they sat square, I could lay the other stile in place, and mark where the mortises needed to go. Then a lot more chopping to do. Finally clamped the whole mess together, using the jig to steady things

Close, but will take a bit more fitting up. Once that is done…I get to do the other side the same way. Then, maybe….I can do the back of the end table. Front will be just a door.

I also got some layout on the rear frame and panel. needed to know how wide it will be, based on the width of the top, how much overhang I will use, and how the stiles will add up. leaves about 10-1/2" or so for the three rails. Counting their 1" tenons. Hey, I even wrote a couple things down ON paper today…..

Once I get the frames all nice and "happy, happy" I can raise a few panels. maybe this time next week….we might try some assembly! Til then, stay tuned…

Click to expand...

bandit571 said:

Frame and panel work

Well, last time, I had a couple frames almost done. I went down to the shop a couple times today. Got the second large frame all joinered up. Then worked on the narrow end frame..

This is from laying out where the rails would go. First I had to trim them to length. Got out a mitresaw..

A little old school, but it works. Had a plain candle handy, and before most cuts, I'd rub the saw with the candle. Made sawing thos oak a breeze. Cut a few tenons with that same saw. hey, it was out, might as well use it. Saw the lines, pop off the waste with a chisel, pare flat. Saw a haunch on the upper and lower tenons. Middle one doesn't need it. Laid out some toys….er..I mean TOOLS

That three piece "jig" is to hold the stiles in place, while I chop a few mortises. It is a tight fit, but a large C clamp did help out. test fit as I went. Takes a while to dig down almost an inch. The one mortise chisel USED to have a leather washer on the end of the handle, used being the operative word. it went flying past me onto parts unknown. I used the wider chisel to clean the sides of the mortise..

Once everything fits. added a clamp to keep it that way. Needed to spread the large frames out a bit.

They are both there, sitting ON the table's top. I needed to measure what size blank I needed to make a couple raised panels. Came out as 22-1/4 long, by 6-1/4" wide. Had a plank of 1/2" thick Oak…Cut the two long panels out, and had enough left over to make one skinny one

yeah, something like that. Ok, got them the right length, need to slim them dowm a bit. Clamped a blank to the bench, marked a line, and grabbed a saw…

Yes I do have a hand powered one, but, I'd rather use a different "Vintage saw".

Clamped the blank to the bench a little bit differently. Marked a line 1-3/8" in from the end. The line is a "stop line", as I raise panels using a plane

I go at an angle to the grain, until a nice bevel shows up. I check with a scrap stile..

Lets me know when the edge is thin enough to fit in the grooves around the frames. i do both ends first. Just turn the blank around then plane the second end. Then, I needed a small block attached to the bench. Wasn't enough room to clamp the blank for the next part..

With the grain. I started out with a Stanley #6c to hog most of it off, then went at it with the smooth plane, again, checking as I went

Almost done when the two bevels meet as a 45 degree line, right to the corner. Then rotate and do the other edge. Panel should look like this

When done. No back bevel or rebate. Got one done, set it aside, and went to town on the second one.
When they were both done, I laid them ON the frame they will be going in..

And I think I called it a night.. I can start again another day. The bevel trick came from Paul Sellers, as this is how he makes raised panels. He uses just a Stanley #4….I use something a bit different..

A Millers Falls No.9. About the same size. Trick is to set it a bit deep to start, then back it off near the end. Makes a LOT of this stuff, though..

Well, that is enough fun for today, stay tuned, we might just get something more done…

Click to expand...

bandit571 said:

The narrow end gets done

Well, at least it is now in a few clamps.

Started off the day checking over the two side panels, now that they are out of the clamps….One was a bit wider at the bottom? Ok, scribed a line to match the other panel. Saw the extra stuff off. Rail was too long at the bottom. 1/4" down to 0" along one side. Dressed the saw marks with a plane. leveled the glue joints up. with a plane, and a sander with 60 grit pad. Got both looking spiffy, compared to last night.

And this

So, today they look a bit better, all cleaned up

yep, there are two of them sitting there. Still have some fine tuning to do. Right now, I need the end panel done, so I can take some measurements and start on the door…later. Cut out another thin oak panel, beveled the four edges to make it a raised panel. had to go back, a rework the first one, as it was a hair too long.

Set up the"Clamping Bench" once again. Might get the hang of this..someday.

Had to add a few extras…

The F style clamp is to keep the panel from bowing. The two C clamps are for filler strips. There is a gap there. used a thin strip to fill in the gap. Clamps to push them in place until the glue dries. later, I can plane them flush.

Next up? After the narrow panel is finesed up, then I can start on a door. There is a shelf to install at the bottom edge. I get the supports installed, and the shelf added. Then figure a way to add the top.

Corner joints will be counter-bored screws, with plugs to cover them. Have to decided whether to hide the plugs, or show them off. We getting there…SLOWLY.

Stay tuned…

Click to expand...

bandit571 said:

The narrow end gets done

Well, at least it is now in a few clamps.

Started off the day checking over the two side panels, now that they are out of the clamps….One was a bit wider at the bottom? Ok, scribed a line to match the other panel. Saw the extra stuff off. Rail was too long at the bottom. 1/4" down to 0" along one side. Dressed the saw marks with a plane. leveled the glue joints up. with a plane, and a sander with 60 grit pad. Got both looking spiffy, compared to last night.

And this

So, today they look a bit better, all cleaned up

yep, there are two of them sitting there. Still have some fine tuning to do. Right now, I need the end panel done, so I can take some measurements and start on the door…later. Cut out another thin oak panel, beveled the four edges to make it a raised panel. had to go back, a rework the first one, as it was a hair too long.

Set up the"Clamping Bench" once again. Might get the hang of this..someday.

Had to add a few extras…

The F style clamp is to keep the panel from bowing. The two C clamps are for filler strips. There is a gap there. used a thin strip to fill in the gap. Clamps to push them in place until the glue dries. later, I can plane them flush.

Next up? After the narrow panel is finesed up, then I can start on a door. There is a shelf to install at the bottom edge. I get the supports installed, and the shelf added. Then figure a way to add the top.

Corner joints will be counter-bored screws, with plugs to cover them. Have to decided whether to hide the plugs, or show them off. We getting there…SLOWLY.

Stay tuned…

Click to expand...

bandit571 said:

The narrow end gets done

Well, at least it is now in a few clamps.

Started off the day checking over the two side panels, now that they are out of the clamps….One was a bit wider at the bottom? Ok, scribed a line to match the other panel. Saw the extra stuff off. Rail was too long at the bottom. 1/4" down to 0" along one side. Dressed the saw marks with a plane. leveled the glue joints up. with a plane, and a sander with 60 grit pad. Got both looking spiffy, compared to last night.

And this

So, today they look a bit better, all cleaned up

yep, there are two of them sitting there. Still have some fine tuning to do. Right now, I need the end panel done, so I can take some measurements and start on the door…later. Cut out another thin oak panel, beveled the four edges to make it a raised panel. had to go back, a rework the first one, as it was a hair too long.

Set up the"Clamping Bench" once again. Might get the hang of this..someday.

Had to add a few extras…

The F style clamp is to keep the panel from bowing. The two C clamps are for filler strips. There is a gap there. used a thin strip to fill in the gap. Clamps to push them in place until the glue dries. later, I can plane them flush.

Next up? After the narrow panel is finesed up, then I can start on a door. There is a shelf to install at the bottom edge. I get the supports installed, and the shelf added. Then figure a way to add the top.

Corner joints will be counter-bored screws, with plugs to cover them. Have to decided whether to hide the plugs, or show them off. We getting there…SLOWLY.

Stay tuned…

Click to expand...

bandit571 said:

Narrow end came out of the clamps...

And started to seperate at a couple joints! Ok, we have ways to deal with that. Clamps back on, to pull the parts back together. Then, to keep things in place, I have a little trick. Made sure that the side that was "up" was the inside of the panel. A few 5/8" long brads, three per joint, were driven in. I also, before the nails, flush the filler piece. Once all the nails were in and set, the sander took over. Everything nie and flat.

Turned the panel over, clamps and all. handplane to flush the joints down flat. Including the filler strip. then a bit of sanding, as needed. Some of the edge were a bit ragged looking…

let this mess set for awhile…

Came back down after supper. Panel was NOW ready to leave the clamps. needed a place to set it for a bit.

boss will get mad, I set it ON HER Washer! Neede to trace some details out. Had a plank of oak, 7/8" thick. needed a couple curvy parts made. They are to match the foot details elsewhere on the endtable. I also wanted a bit extra, to make a connection with. Scrollsaw does NOT like 7/8" white oak…had to sand the parts a bit, to even out the cuts.

I also has a 1×2 strip of oak, needed it cut down to a correct length….Disston No.5 would not cut a straight line as a crosscut saw…more cuts to sand…

The fancy joint to connect these three pieces? Involves a few saw cuts ( rip cuts this time) wax up the saw, and away we go…

Two cuts were easy. Then a few whacks with a chisel on each curvy part, and we have this.

Not too worried about having the groove centered, as the next step will match whatever I have. Two cuts down on the end, then a saw cut to remove the outside waste. A chisel to clean things up. MARK which end this goes to. Nice DARK pencil line across BOTH parts at the joint. The rotate the 1×2 and do the other end. When done, it is supposed to look like this..

Got both ends looking halfway decent, time for clamps nails, and glue. Maybe not in that order.

First clamp. hammer to keep it flat, and a single 5/8" brad into each joint. Noticed something wasn't quite right.

Tape measure showed the ends spreading out a bit, maybe 1/4"?? Need another clamp!

And crank on it for a bit. Top read was 12-15/16", needed the bottom to move inalmost 5/16"! The leg vise kept things from getting squirrelly on me. Final check? Both match, quitting time!

Maybe tomorrow, I can hide out in the shop, and get the door built? Maybe?

Stay tuned, at this Speed of Randy pace, I might be ready for a finish by the weekend?? Maybe.

Click to expand...

bandit571 said:

A test fit, and some assembly

Moving right along, now. I checked the narrow panel end for square…..zero to 1/4" along one side, zero to 1/16" along the other side. Circular saw to rough the wider one back to square, not going to worry about the barely there one. Clamped the panel into the leg vise, added a clamp out in front, #5-1/2 jack plane to joint the edge. I think I can try a test fit of all the built-so-far parts..

As for that top laying under everything?, well, the #5-1/2 went to town on it, to get both faces flat(almost)

Okay, laid out a bunch of marks along the corner's ends. 3/8" Forstner bit to drill some counter bores. Then a pilot hole. Apply a bead of glue on the non-drilled part ( held in place with a clamp or two) and then added a few screws.

Once all four corners were screwed and glued, I could stand this thing up on it's own four feet

Added the top bar above the door opening. Then made a couple (for now) corner blocks to hold it in place

Screwdriver collection? Two screws and some more Elmers to hold things in place. I also added a cleat to hold a floor

I'll run cleats all the way around. Need two more corner blocks made. I add a slotted hole in them, and attach the top that way.

hey, we are making a bit of progress…I think. Stay tuned…

Click to expand...

hey, we are making a bit of progress…I think. Stay tuned…

- bandit571

Click to expand...

bandit571 said:

A test fit, and some assembly

Moving right along, now. I checked the narrow panel end for square…..zero to 1/4" along one side, zero to 1/16" along the other side. Circular saw to rough the wider one back to square, not going to worry about the barely there one. Clamped the panel into the leg vise, added a clamp out in front, #5-1/2 jack plane to joint the edge. I think I can try a test fit of all the built-so-far parts..

As for that top laying under everything?, well, the #5-1/2 went to town on it, to get both faces flat(almost)

Okay, laid out a bunch of marks along the corner's ends. 3/8" Forstner bit to drill some counter bores. Then a pilot hole. Apply a bead of glue on the non-drilled part ( held in place with a clamp or two) and then added a few screws.

Once all four corners were screwed and glued, I could stand this thing up on it's own four feet

Added the top bar above the door opening. Then made a couple (for now) corner blocks to hold it in place

Screwdriver collection? Two screws and some more Elmers to hold things in place. I also added a cleat to hold a floor

I'll run cleats all the way around. Need two more corner blocks made. I add a slotted hole in them, and attach the top that way.

hey, we are making a bit of progress…I think. Stay tuned…

Click to expand...

bandit571 said:

Final assembly, and aPIP?

Got to get this thing done! Spent the whole day, fixing the door with a handplane. Added cleats to hold a floor

Then cut and install a couple floor boards

Didn't have enough plywood. Planks are 1/2". Screwed in place,but no glue. Got the corner blocks all installed

I can then cut slotted holes. Just drill a hole in center of the block, then rock the drill back and forth towards the sides. This allows the top to expand and contract as it wants. A single screw in each to hold the top.

Dug out the router….could NOT get the collar out of the fixed base. Ok, Ve haft Vays..

I took the motor out of the fixed base, and slid it into the plunge base. Pays to buy a kit. Both bases came with this router. Got the router all set up. Needed to cut a few plugs to cover a few screw holes. Chucked a bit into the drill press, and made a bunch of 3/8" tapered plugs . Used the same wood as the case. Pop a plug out, glue it up, tap it down into the hole. Chisel to pare it flat. Then sanded smooth. Dried glue is a bear to get off my planes. All plugs done. Time to run a few edges with the router

Around all the feet, along the bottom edges, and up the corners. Flip it over a few times, until it wound up on the top. Four screws to secure the top. Flip this 40 pound wonder over, and router the edges. Note: while the case was on it's side, I used a beltsander to round the corners of the top a bit. Had to switch the case around, to do the edges I couldn't get to.

Went and dug up some hinges. Found the right size pilot drill bit. Installed the hinges. Adjusted the door a bit, as the lower corner away from the hinges wanted to stick a bit. Final sanding to get rid of fuzzy things, add a knob on the door…we have a PIP!

Hauled this beast upstairs, too dusty, and damp down in the shop. Trying to talk the Boss out of PAINTING this!!!??? As for the shop?

Well,well, well…long time no see. been how long since I've seen that bench's top???

I think I am done with the woodworking on this project. Top did have a knot hole in it, clear through the top. Cut one more plug, and glued it down. Works for me.

Thanks for following along. After the finish is on…maybe post this as a project?

Click to expand...