DIY Network

Trestle Table: Curved Trestle; Base Assembly From "Wood Works" episode WWK-704

In this episode of DIY Wood Works, host David Marks creates an Asian-inspired trestle table from curly maple. This second episode segment focuses creating the shaped trestle and assembling the table base.

Materials used in this episode:

Maple stock
Pernambuco stock for inlay
MDF for templates
Table saw
Dado-blade for table saw
Band saw
Jointer
Drum sander
Table router; flush-trim bit, & 1/8" round-over bit
Plunge router
Oscillating spindle sander
Random orbit sander
Jig saw
Drill press
Cordless drill
Hand scraper
Spoke shave
Sharp chisel
Pattern-maker's rasp
Italian riffler file
Sanding strip; sandpaper
Dead-blow hammer
Carpenter's square
Flexible bending stick
Clamps and wood-cauls
Yellow woodworker's glue
Cyanoacrylate glue
Straight-edge
Carpenter's pencil
Chalk
Double-stick tape
Carpenter's masking tape
Wood finish: commercial blend of tung oil, linseed oil and urethane
Paintbrushes and rags
Safety glasses or goggles
Protective gloves

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

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Figure A

The Curved Trestle

For design, the trestle that connects between the legs is shaped with curves. To create these curves, another set of templates is fashioned from MDF (figure A) -- one for the top and bottom profile, and another for the sides.

• An angle is cut on each end of the trestle (figure B).

• While the stock for the trestle is still square, adjust the angle on the miter gauge to 75 degrees. Using a 40-tooth combination blade, make the angled cut (figure C) on both ends of the trestle.

  Figure B

  Figure C

  
  

• With the trestle on its side, trace on the shape of the template that defines the top and bottom curves (figure D).
  
  
• Rotate the trestle, and outline the second template -- the one that defines the curves of the sides.

• At the band saw, cut out the profile of the top and bottom (figure E).

  Figure D

  Figure E

  
  

• Once the cuts for the top and bottom are complete, tape the fall-off back onto the stock.
  
  
• Tilt the bed of the band saw to 10 degrees, and carefully cut out the curves in the sides (figure F).

• Remove all of the fall-off to reveal the rough shape of the trestle (figure G).

  Figure F

  Figure G

  
  

• An oscillating spindle sander is the perfect tool for removing the saw-marks left by the band saw. To match the angle already cut on the sides of the trestle, tilt the bed of the sander to 10 degrees (figure H).
  
  
• Refine the shape using a random orbit sander.

• To break and round over the edges, use a spoke shave (figure I).

• Finish up the sides using a sanding strip and 220-grit sandpaper to soften the edges.

  Figure H

  Figure I

  
  

  Figure J

• With the trestle and legs complete, you can conduct a dry-fit of the table base (figure J). Use the dry-fit process to work out your clamping strategy. The unusual shape of this base can present a clamping challenge.
  
  
• After a successful dry-fit, take the pieces apart and do some final refining of the surfaces using 220-grit sandpaper.
  

• So that gravity works in your favor, assemble the base on ones side.

• Apply yellow glue to the leg slots, biscuits and dados (figure K).
  
  
• Set the trestle into the dados (figure L).

  Figure K

  Figure L

  
  

• Assemble the final side (figure M), sliding it onto the biscuits and into the matching dados. Use a dead-blow hammer to help set them in place.
  
  
• Add even pressure with clamps (figure N).

  Figure M

  Figure N

  
  

  	Figure O
  	Figure P

While the glue on the base is drying, you can shape the stock for the tabletop that was cut out earlier.

• Use a straight-edge and ark a center line down the length of the stock.

• Measure for center, and draw on an intersecting line.

• Mark out the position where the legs will join the top (figure O).

• Align the MDF template made earlier, and trace out the shape (figure P).
  

• Cut out the shape, close to the line, using a jig saw (figure Q).

• Double-stick tape the template to the stock, then smooth the edges at the router table using a flush-trim bit.

• Replace the bit with a 1/8" round-over bit and use it to shape the edges (figure R).

  Figure Q

  Figure R

  
  

RESOURCES :

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

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

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com