| Inlaid Corner-Table -- Template and Joinery |
From "Wood Works"
episode WWK-310 |
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In this episode of DIY Wood Works, host David Marks builds an elegant corner table that features an ebony inlay on top. This piece is fashioned in the arts-and-crafts style, and provides the woodworker with opportunities for working with decorative inlays, mortise-and-tenon joinery and legs tapered on all four sides. The legs, apron and top are all made from solid cherry. The triangular top features squared off corners and softened edges. The project consists of three main assemblies: - The legs, featuring a four-way taper;
- the apron;
- the top, with ebony inlay.
Materials:
Cherry stock
MDF for template
Table saw
Jig saw Plunge-router
Clamps
Straight-edge
Carpenter's pencil
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, power-tools, saws, drills, routers, etc.
MDF Template for the Top
- The first step is to create a template for the top. To create the template, draw out a triangular shape onto a 1/2-inch sheet of MDF. The dimensions of the triangle are 40 inches long (across the face) by 21 inches deep. Rough-cut the template using a jig saw (figure A).
- To flush-trim the edge, first clamp a straight board to the MDF for reference. Then, flush the edge smooth using a plunge router (figure B). The bearing rides along the straight board as the bit trims the excess.
- From the basic triangular shape, finalize the layout using a piece of blank cherry leg-stock that has been milled to 1-1/2 inches square. Position the leg so that there's a 3/8-inch reveal around each side (figure C), and make layout marks with a pencil. Use the piece of stock to lay out the position of each of the three legs. The layout marks define the areas trimmed off to make two of the corners square.
- Keeping in mind that the final table-top should be 1/2-inch larger than the base, finish the template by connecting the leg-layouts with a straight-edge ruler (figure D).
- The straight layout marks that join the marks for the legs (figure E) represent the position of the aprons.
- Once all of the layout marks have been drawn onto the template, trim off the two front corners using the table saw (figure F).
- Now that the template is complete, work can begin on the elements for the base. As seen in the prototype (figure G), the base is made by joining three tapered legs to three aprons using mortise-and tenon joinery. Two of the aprons are joined to their adjoining legs at 90-degree angles, while the remaining one is joined at either end with 45-degree angle-cuts.
Leg and Apron Stock; Joinery
- The leg-stock is milled 1-1/2 inches square. The joinery is cut before the tapers are cut in the legs.
- At the four locations where the apron meets the legs on the 90-degree face, the mortises are cut in the center of the apron (figure H).
- The two mortises on the legs that connect the front apron at 45 degrees are slightly offset to the inside of the apron (figure I) to allow the full depth of the mortise.
- At the workbench, a jig made from MDF is used for cutting the mortises in the legs. The straight edge of the jig (figure J) serves as a guide for the fence of the plunge router, providing a flat cutting-surface.
- Use a 1/4-inch bit, set at a 1/2-inch depth, to cut the mortise in several passes using the plunge router (figure K).
- With the mortises cut in the leg-stock, work can now begin on the aprons. The apron stock is jointed, planed and milled to a final dimension of 3/4-inch thick and 3 inches wide. Set the apron-stock pieces onto the template (figure L) to make the layout marks needed for cutting the apron stock to length.
- To cut the ends of the front apron (that joins the legs at 45-degree angles), set the blade on the table-saw to 45-degrees (figure M) and make the cuts on either end to cut the piece to length.
- Cut the two back aprons (that join their adjacent legs at 90-degree angles) to length with table-saw and cross-cut sled -- with the saw blade set at 90 degrees (figure N).
- Now, cut the mortises into the ends of the apron stock. The cutting jig enables the router to utilize a flat cutting surface that references a straight edge. Measuring down 1/4-inch from the top edge, cut the mortise 2-1/2 inches long in the center of the stock using a plunge router.
- For the front apron, a mortise cut at 90 degrees will need to be made in the 45-degree face. To make this cut, use the existing jig. Clamp the apron stock into a vise at a 45-degree angle, and push the end of the stock up into the hole in the jig. This will provide a flat cutting surface for making the mortise (figure O ). Again, cut the mortises 2-1/2 inches long, cutting in several passes.
- Make the tenons from cherry stock that has been milled 1/4-inch thick by 2-1/2 inches wide. At the router table, round the edges of the tenon stock with a 1/8-inch round-over bit to match the mortises in the legs and aprons (figure P).
- Cut the tenons to length at the table saw. Each tenon should be 1 inch long ( figure Q).
- With all of the joinery cut, conduct a dry-fit to ensure that the pieces line up and fit together properly.
In the segment that follows, the tapers are cut in the legs and the top piece is cut.
Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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