DIY Network

Sewing Table Construction From "DIY to the Rescue" episode DTTR-511F

With the floor complete, host Amy Devers and Trudy can tackle the real heart of the basement sewing room operation–the sewing tables. Essentially, they're creating mounted work benches on casters to create mobile units with work and design flexibility in mind.

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	The basement began as a cluttered hobby room.
	It's now a relaxed, professional workspace.
	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Materials:

circular saw
drill/driver
drill bits
belt sander
clamps
wrench
tape measure
dust mask
safety goggles
hearing protection
2x4 lumber
2x8 lumber
4 sheets 1/2" golden birch plywood
16- 3/8"x4" carriage bolts with washers and nuts
wood glue
3" wood screws

Cut List:

Cut the pieces, using the measurements below or your own custom measurements.

4- 1/2" golden birch plywood cover — 60" by 30"
18- 2x4s for the top substrate — 57"
2- long 2x8 top rails — 60"
2- short 2x8 top rails — 27"
2- 2x4 rail stretchers — 27"
8- 2x4 leg pieces — 30"
2- long 2x4 bottom rails — 54"
2- short 2x4 bottom rails — 21"

Sewing Table Construction

1. Glue the 2x4s in sets of five. After all the sets have cured, glue them together to create the full top substrate assembly. Face-glue and clamp the 2x4s for the top substrate so they give the appearance of a butcher-block top. The substrate gives the bench strength and stability.

2. Use a belt sander or hand plane to flatten the top of the substrate. Lay the substrate out, top side down. Align the short 2x8 top rails flush with the short sides of the substrate and use 3" wood screws to secure the rails to the substrate (figure A).

3. Align the long 2x8 top rails with the long sides of the substrate. The ends of the long top rails should be flush with the outside face of each short top rail. Secure the long top rails to the substrate with 3" wood screws.

4. Insert the rail stretchers between the long rails, positioned 1/3 of the way in from each end of the bench. Drive 3" wood screws through the long rails into the ends of the rail stretchers.

5. Construct four leg assemblies (figure B). Butt the edge of one 2x4 leg piece to the face of another and line the ends up flush. Screw the leg pieces together with 3" wood screws.

6. Set the legs inside the corners where the long and short top rails meet (figure C). The joints between the leg assemblies should be visible from the short sides of the bench. Bore 3/8" holes through the top rails and legs. Insert 3/8" x 4" carriage bolts from the outside face of the top rails through the leg pieces. Install a washer and nut on the backside of each carriage bolt and tighten.

7. Measure 12" from the bottom of each leg and mark. Align the tops of the long 2x4 bottom rails flush with the marks and use 3" wood screws to secure the rails to the legs.

8. Insert the short 2x4 bottom rails between the long 2x4 bottom rails. The outside face of the bottom rail should butt to the inside face of the leg. Secure the short rails to the legs with 3" wood screws.

9. Stand the workbench right side up (figure D). The bench will be heavy, so have someone help you. Align the edges of the 1/2" plywood top flush with the edges of the bench. Secure the top to the substrate with 1" flathead screws (figure E). If the plywood top is damaged later, it's a simple task to remove and replace it.

Assembling Sewing Table Top

Materials:

3-inch foam board
heavy-duty canvas
felt
staple gun
scissors
iron

1. Position the foam and then lay the felt and canvas layer on top. Trim the material to size, leaving about six inches of excess to secure later (figure F).

2. Stretch the canvas taut across the top of the table before securing it with upholstery staples. For a more finished look, fold the canvas under once before securing it to the plywood top. Alternate stapling out each side until the entire perimeter has been fastened firmly–saving the corners for last.

3. The final step is a bit like making a bed–a nice, tight, hospitable bed corner and the top is officially in place. It looks great (figure G)!

RESOURCES :

Verilux Lighting Systems
Website: www.verilux.com

Natural Cork Flooring
Website: www.naturalcork.com

Mills Pride
Website: www.distinctionscabinetry.com

HITACHI Power Tools
Website: www.hitachi.com

Porter Cable Power Tools
Website: www.deltaportercable.com

Delta Power Tools
Website: www.deltaportercable.com

Klein Tools
Website: www.kleintools.com

Magnetic Alliance Brand Integration
We apologize no contact information is available.

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Benjamin Moore Paint
Website: www.benjaminmoore.com