2534_Oc_Table_MV6.pdf

WOODWORKS: INTERMEDIATE PROJECT 2008-2009

OCCASIONAL TABLE

Here’s a nice, small-sized table that can be put to good use in many rooms, from bedrooms to living and family rooms. And its traditional yet

clean-lined design will help it to go well with any decorating style.

Making one of these tables will be an excellent exercise for intermediate woodworkers because it entails several techniques that will increase your

skills: tapering the table legs, making single- and double-biscuit joints, making a solid wood panel, plus making grooves and rabbets. And when

it’s all assembled, you’ll learn more about applying and using stains and finishes to protect the wood and keep it looking beautiful.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2008-2009 OCCASIONAL TABLE

TOOLS REQUIRED

SHOPPING LIST

Wood Recommendation: Maple and walnut (panel)

Alternate Wood: Oak and mahogany (panel)

4 lin. ft. 8/4x4

10 lin. ft. 5/4x4

3 lin. ft. 1x4

4 lin. ft. 1x4 walnut or mahogany

#20 biscuits, 30 pcs.

Hand Tools

Bar and C-clamps

Wood or rubber mallet

Power Tools

Table saw

Band saw

Jointer

Biscuit joiner

Random-orbit sander

Miscellaneous

– Pencil

– Tape measure

– Safety glasses

– Carpenter’s glue

– 120-, 150- and 220-grit sandpaper

– Clean, lint-free cloths

– Respirator

– Gloves for finishing

– Mineral spirits (for oil-based stains

and finishes)

– Water-filled metal container with

tight-fitting lid (for oil-based stains

and finishes)

– Minwax ® Wood Finish ™ Stain Brush

or other good quality, natural-bristle

brush (for oil-based stains and

finishes)

CUTTING LIST

Overall dimensions: 18" x 18" x 19"

Item Description

Size & Quantity

Leg

1-3/4" x 1-3/4" x 19", 4 pcs.

Apron

1" x 3" x 12-3/4", 4 pcs.

Long frame

1" x 3" x 18", 2 pcs.

Short frame

1" x 3" x 12", 2 pcs.

Panel

5/8" x 12-1/2" x 12-1/2", 1 pc.

Gluing blocks

3/4" x 3/4" x 3", 8 pcs.

WOOD FINISHING PRODUCTS

Recommended Finish

Prep: Minwax ® Pre-Stain Wood Conditioner

Stain: Minwax ® Gel Stain Cherrywood

Minwax ® Gel Stain Brazilian Rosewood (center tile)

Finish: Minwax ® Fast-Drying Polyurethane

Alternate Finish

Prep:

Minwax ® Pre-Stain Wood Conditioner

Stain:

Minwax ® Polyshades ® Mission Oak

Minwax ® Polyshades ® Pecan (center tile)

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BEFORE YOU BEGIN

Good craftsmanship begins and ends with good work habits, so make

the following steps part of your routine workshop practice. If you have

any doubts or questions about how to proceed with a project, always

discuss them with your shop instructor.

• Carefully and fully review plans and instructions before putting a

tool to the project lumber.

• Work sensibly and safely. Wear safety goggles when doing work

that creates flying chips and sawdust; wear the appropriate

respirator whenever making sawdust or working with thinners

or other solvents.

• At the end of every work session, clean up your shop area and put

away all portable tools.

recess for the panel (see Fig. 1). The groove in the long frame pieces

must be stopped so it doesn’t show through the end grain.

9. Cut the panel material to the required lengths (E). Joint the edges to

make them perfectly straight and square. Cut two biscuit slots into each

edge (except the outside edges of the pieces that will be used for the

outside edges of the panel). Glue and insert the biscuits, glue the edges

and clamp all the pieces together. Wipe away excess glue before it dries.

10. When the panel glue has dried, cut the panel to the final dimensions

on the table saw. Then equip the saw with a dado blade and set it to cut

a 1/2" - deep x 1/2" -wide rabbet along the edges of the panel (see Fig. 1).

Test the fit of the resulting lip in the grooves of the frame pieces. It

should be snug but not too tight.

CUTTING AND ASSEMBLY

PROCEDURE

1. Saw the 8/4 material for the legs (A) 1/8" oversize. Then joint, plane

and cut them to the final size.

11. Before assembling the frame and panel pieces, finish-sand the

exposed inside edges of the frame and the top face of the panel. It’s

easier to do this now than after the tabletop is assembled. You must

also stain and finish the center panel before it is enclosed by the

frame pieces.

2. Mark an X at the top of two adjacent sides on each leg. The tapers

are subtle and it’s possible to confuse them with the untapered outer

sides. Also, where the tapered sides join the aprons, they must be

untapered (see Fig. 1), so the taper cuts must stop 3-1/2" from the

top of each leg.

12. Glue and insert the biscuits and the ends of the frame pieces.

Assemble the frame pieces around the panel and clamp the corners

tightly together. Wipe away excess glue before it dries. After the glue is

dry, finish-sand the frame so that all the joints are perfectly smooth.

3. Mark lines for the tapers on each leg and saw the taper on the band

saw. Stay about 1/16" away from your pencil line (see Fig. 2). Always

use a pushstick when cutting narrow boards. After the first taper is cut,

reattach the resulting scrap with masking tape and cut the second taper.

Remove band saw marks with a pass or two over the jointer.

13. Cut the gluing blocks (F) to size and glue them to the inside faces

of the apron, two per side (see Fig. 1).

14. When the glue has dried, apply glue to the top edge of the apron,

and the tops of the gluing blocks and legs. Position the tabletop so that

it overhangs the table base equally on all sides, and use deep C-clamps

to secure the assembly. Wipe away excess glue before it dries.

4. To cut the double biscuit slots in the legs, use spacers as shown in

Figure 3. This setup works with any biscuit joiner and the only measur-

ing you need to do is to locate the centerline of the slots, measuring

down 1-1/2" from the top of the legs. Cut the first slot using the 1/4"

spacer. Then put the 3/8" spacer on top of it and cut the second slot.

Each leg will thus have two pairs of slots. Make sure to cut the slots

with the adjacent tapered side of the leg side down on the worktable.

Use a clamp to hold the leg while you work.

STAINING AND FINISHING

Woodworker’s Tip: Though you may be tempted to cut short

your sanding, preparation and application time, don’t do it. These

tasks are very important steps in obtaining a high-quality finish.

Remember, it is the finish, just as much as the fit and smoothness

of the parts that will have great bearing on how people judge your

craftsmanship. To ensure an excellent result, follow the steps

listed in this section and also the instructions the finish manu-

facturer puts on its products.

5. Cut the aprons (B) to length from the 5/4 stock. To cut the double

biscuit slots in the ends of the aprons, clamp the apron face-side down.

Cut the first slot without the 1/4" spacer; then put the 3/8" spacer in

place to cut the second slot (Fig. 4). This is a foolproof system for

making the slots in the legs and aprons exactly the same distance apart.

FINISHING TIPS

• Test the stains and finishes you are planning to use on scraps of

wood. On the back of the scrap, mark the stain/finish combination

and the type of wood. Allow all samples to dry thoroughly before

making your final finish selection. Save your samples for quick

reference on future projects.

• All stains and finishes must be allowed to dry thoroughly between

coats. Remember that drying times can vary due to humidity and

other climatic conditions.

• If you have some leftover stain or finish, wipe the can rim so that

stain or finish in the rim won’t dry out and prevent the lid from

forming a tight seal.

• Brushes used for oil-based finishes must be cleaned with

mineral spirits.

6. Glue the legs and aprons together one side at a time. Wipe away

excess glue before it dries. After the glue has dried, complete the table

base by gluing and clamping the remaining two apron pieces (Fig. 5).

7. Cut the long (C) and short (D) frame pieces to the required length

and width. Cut double biscuit slots into the ends of the short frame

pieces and into the edges of the long frame pieces. Use the same

technique described in step 5.

8. Cut 1/4"-wide x 3/8"- deep grooves into the inside edges of all the

frame pieces, 1/4" down from the top face of the frame to create the

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2008-2009 OCCASIONAL TABLE

15. Finish-sand any remaining rough spots with 220-grit paper. Dust

off the piece and wipe it carefully with a clean, lint-free cloth lightly

dampened with mineral spirits.

WARNING! Removal of old paint by sanding, scraping or other means

may generate dust or fumes that contain lead. Exposure to lead dust

or fumes may cause brain damage or other adverse health effects,

especially in children or pregnant women. Controlling exposure to lead

or other hazardous substances requires the use of proper protective

equipment, such as properly fitted respirator (NIOSH approved) and

proper containment and cleanup. For more information, call the

National Lead Information Center at 1-800-424-LEAD (in U.S.) or

contact your local health authority.

Recommended Finish

16. Apply Minwax ® Gel Stain Cherrywood to the table frame and Minwax ®

Gel Stain Brazilian Rosewood to the center panel using a clean, lint-free

cloth or natural-bristle brush. Follow the directions on the can. Allow

the Gel Stain to set for about 3 minutes, then wipe off any excess with a

clean, lint-free cloth. To achieve a deeper color, you may apply a second

coat after 8 to 10 hours, repeating the application directions for the

first coat. Allow the stain to dry for 24 hours before applying the finish.

DANGER: Rags, steel wool, other waste soaked with oil-based stains

and clear finishes, and sanding residue may spontaneously catch fire if

improperly discarded. Immediately place rags, steel wool, other waste

soaked with this product, and sanding residue in a sealed, water-filled

metal container. Dispose of in accordance with local fire regulations.

Woodworker’s Tip: When wiping off stain, make certain that

your last wipe with the cloth goes with the grain of the wood. This

way, any stain you might miss during wipe-off will be visually

minimized by the wood grain.

When using oil-based wood finishing products:

CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS.

Contents are COMBUSTIBLE . Keep away from heat and open flame.

VAPOR HARMFUL . Use only with adequate ventilation. To avoid over-

exposure, open windows and doors or use other means to ensure fresh

air entry during application and drying. If you experience eye watering,

headaches, or dizziness, increase fresh air, or wear respiratory

protection (NIOSH approved), or leave the area. Avoid contact with

eyes and skin. Wash hands after using. Keep container closed when

not in use. Do not transfer contents to other containers for storage.

17. Apply Minwax ® Fast-Drying Polyurethane following the directions

on the can. Use a good quality, natural-bristle brush. Allow the first coat

to dry overnight.

18. The next day, sand all surfaces lightly with 220-grit or finer sandpa-

per using with-the-grain strokes. Dust off and wipe all surfaces with a

cloth lightly dampened with mineral spirits. Apply a second coat of

polyurethane and set the piece aside to cure overnight.

19. The following day, sand all surfaces lightly with 220-grit paper.

Dust off and wipe the piece with a cloth lightly dampened with mineral

spirits and apply the third and final coat of polyurethane.

FIRST AID: In case of eye contact, flush thoroughly with large

amounts of water for 15 minutes and get medical attention. For skin

contact, wash thoroughly with soap and water. In case of respiratory

difficulty, provide fresh air and call physician. If swallowed, call Poison

Control Center, hospital emergency room, or physician immediately.

Alternate Finish

20. Apply Minwax ® Polyshades ® Mission Oak to the table frame and

Minwax ® Polyhades ® Pecan to the center panel following the direc-

tions on the can. Use a good quality, natural-bristle brush suitable for

use with polyurethane. Stir the can contents thoroughly before starting

and periodically repeat stirring during your work session. Allow the

first coat to dry overnight.

DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.

Contains solvents which can cause permanent brain and nervous

system damage. Intentional misuse by deliberately concentrating and

inhaling contents may be harmful or fatal.

WARNING: This product contains a chemical known to the State of

California to cause cancer and birth defects or other reproductive harm.

DO NOT TAKE INTERNALLY. KEEP OUT OF REACH

OF CHILDREN.

CONFORMS TO ASTM D-4326. Contact a physician for more

health information.

21. The next day, sand all surfaces lightly with 220-grit sandpaper or

very fine (000) steel wool using with-the-grain strokes. Dust off and

wipe all surfaces with a cloth dampened with mineral spirits. Apply a

second coat of Polyshades ® and set the rack aside to cure overnight.

To achieve a deeper color, you may apply a third coat after 4 to 6 hours,

repeating the application directions. Allow the table to cure for several

days before using it.

When using water-based wood finishing products:

CAUTIONS: Use Only With Adequate Ventilation. To avoid overexpo-

sure, open windows and doors or use other means to ensure fresh air

entry during application and drying. If you experience eye watering,

headaches, or dizziness, increase fresh air, or wear respiratory

protection (NIOSH approved), or leave the area. Avoid contact with

eyes and skin. Wash hands after using. Keep container closed when not

in use. Do not transfer contents to other containers for storage.

Woodworker’s Tip: If you achieve the desired color on the first

or second coats of Polyshades ® , apply a clear coat of Minwax ®

Fast-Drying Polyurethane or Minwax ® Wipe-On Poly for added

protection.

PRODUCT SAFETY

For your safety and the safety of those you work with, always read the

safety warnings, which manufacturers print on their labels, and follow

them to the letter.

FIRST AID: In case of eye contact, flush thoroughly with large

amounts of water. Get medical attention if irritation persists.

If swallowed, get medical attention immediately.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2008-2009 OCCASIONAL TABLE

WARNING: This product contains a chemical known to the State of

California to cause cancer and birth defects or other reproductive harm.

DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF

CHILDREN.

CONFORMS TO ASTM D-4326. Contact a physician for more health

information.

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