DIY Network

End Table Frame Amy constructs and assembles the frame. From "Freeform Furniture" episode DFFF-202

Host Amy Devers cuts the birch plywood parts for the frame, uses the medium density fiberboard (MDF) template to cut the windows for the glass insert, routs the rough edges--and glues and assembles the frame.

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	Amy begins the table top construction by creating the frame.
	Before: Arthur wasn't too particular about where he placed his reading materials before Amy created...
	this unique, urban end table created with plywood, cement and broken automobile glass.

Materials:

birch plywood
plastic push stick
medium density fiberboard
double-stick tape
straight edge boards
pencil
220-grit sandpaper
low tack masking tape
flat latex house paint
white wood glue
brad nails
cement-based finished underlayment
bucket
spray shellac
respirator
packing tape
screws
sheet of glass
broken automobile glass
epoxy
glass cleaner
paper towels
gloves
wax free measuring container
wooden stick
acetone
spacer strips
blue tape
pre-fabricated steel legs

Tools:

table saw
crosscut sled
jigsaw
router
flush trim bit
cordless drill
clamp
table router
trowel
heat gun
staple gun

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Creating the Frame for the End Table

1. Cut all the plywood parts for the frame using half inch birch plywood. Birch doesn't expand and contract like solid wood which is important because expansion and contraction would cause the cement surface treatment to crack over time.

2. Make a cut list (figure A). You can get all the parts out of one sheet of plywood.

3. Set the fence of the table saw, which will guide the wood so that it's parallel to the blade. Maintain firm control while pushing the plywood through the blade keeping the board square to the fence.

4. With the top and bottom pieces for the end table cut to width, reset the fence for the plywood aprons.

5. Feed the piece through the blade using the fence as a guide. As the end of the board gets within six inches from the blade, use a plastic stick (figure B) and guide the wood safely through the blade.

6. With the plywood cut down to width, use the crosscut sled to cut the pieces for the top and bottom of the table. The crosscut sled (figure C) is another attachment for the table saw that helps to cut the wood at a 90-degree angle. It also prevents the piece from pivoting or shifting while you feed it through the blade. Cut the aprons to length making sure the wood is flush to the fence.

7. The parts are cut to size for the plywood frame, and you need to cut windows out of the top and bottom pieces of plywood for the glass insert. Cut a template out of MDF the same size as the table top, and then draw a rectangle the same size of the window.

8. Cut that out with a jigsaw and then double stick tape the straight edge boards along the lines of the rectangle to clean up the jigsaw marks on the router with the flush trim bit.

9. To start making the windows, trace the template onto the table top and bottom.

10. Cut out the interior rectangles with a jigsaw. To make the cutting easier you need to drill holes in each corner (figure D). This will allow the blade to pivot freely when making the sharp turns.

11. Clamp the table top to the workbench and insert the jigsaw blade into the hole and cut out the opening for the glass top. A jigsaw really works great for cutting out any interior shapes.

12. Clean up the rough edges on the router with a flush trimming bit using the template as a guide.

13. Use double stick tape to adhere the template to the plywood table top.

    Note: The trimming bit has a bearing on the top that follows the contour of the template and cleans up the top and bottom inside edges (figure E).

14. Use a 220-grit sandpaper to knock back the rough edges. There are loose fibers and torn out pieces that you need to get rid of before painting and applying the cement finish.

15. Since you don't want to see a color difference when you look through the transparent glass, paint the inside and the bottom parts of the frame. Before painting, mask off the aprons with low tact masking tape. It is important to mask off the aprons because you don't want to get paint on the area where you will be gluing. A clean joint will ensure you get a strong bond.

16. Use a flat latex house paint to paint the underside of the plywood table top and the inside areas of the aprons.

    Note: One reason for painting is that it is generally a good idea to finish things all the way around--you don't want to leave anything unfinished. You need to paint any surface that will not be getting cement. It is also important because certain areas through the glass you will be able to see the other plywood parts, so you need to make sure those are grey--not the blond of the plywood.

17. To finish off the process, cover the interior edge of the plywood and allow the paint to dry for a couple of hours.

18. When everything is dry, glue up and assemble the frame.

19. Remove the tape from the aprons.

20. Apply a bead of white wood glue onto the unpainted area of the apron and adhere it to the table top.

21. To secure the apron, brad nail it in place (figure F).

22. Repeat the gluing and nailing process for the frame of the table top.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Adhesives, Abrasives and Safety Equipment
3M
The 3M Company
Website: www.3m.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

Lie-Nielsen Tookworks, Inc.
Website: www.lie-nielson.com

Wilsonart Laminate
Website: www.wilsonart.com

MacBeath Hardwood
Website: www.macbeath.com