Los Banos High School

End Table

1. Create Frame Use 3/4 inch thick plywood. Cut two pieces to 2-½ inch width and 16 inch length. Cut two pieces to 2-1/2 inch width and 20 inch length.

If you want to create a table of a different size, change the lengths of these boards.

2. Set the boards on edge and make a rectangle shape. Glue and screw frame together. Use countersink/counterbore bit to recess screw heads.

3. Create Table Legs Cut lumber to ¾ inch thick. Cut four pieces to 2-1/4 inch width and 24 inch length. Cut four pieces to 3 inch width and 24 inch length.

These boards can be adjusted to change the height of the table.

4. Joint the edges and glue boards together to create legs that are 3 inches wide in each direction. You will have an L-shaped leg.

5. Cut all four legs to exactly the same length. Use radial arm saw or table saw with the miter gauge.

6. Use router table and a 45 degree chamfering bit to shape the legs. Cut outside edges. There should only be three cuts on each leg. Do not cut inside corners.

7. Sand legs with portable sander and by hand. 80, 120, then 220 grit. 8. Attach Legs to Frame Screw legs to the outside corners of the frame. Use countersink/counterbore bit and drill pilot holes on inside corners of the frame. Check squareness and clamp pieces together before drilling with power drill. Pocket holes may also be used to attach legs to the frame. Use 1-1/4”long screws.

9. With pencil, match the legs and corners of the frame with numbers or letters. Remove all the screws and apply glue, and then screw legs back onto the frame.

10. Create the Stretchers Cut material for the stretchers to 3 inch width. Measure the length between the upper part of the legs to determine necessary length for all four stretchers.

11. Router the two edges and the two ends on the outside surface. Total of four cuts on each pieces. Use the same chamfering bit.

12. Attach the stretchers with screws in the same manner as done previously.

13. Create the Top – 2 options

1) A solid lumber top can be used. Add 4”to the overall width and length of frame. Glue boards to create a top of this size. Plane and sand. Cut top to 3-1/2”longer than width and length. Router top outside edge of the top to match the legs.

2) For a plywood top with banding, measure the width and length of the inside area of the frame. Cut a piece of ¾ inch thick plywood to this size.

14. Cut edging for the top that is ¾ inch thick and 2-1/2 inch wide. Cut two boards to 24 inch length and two boards to 28 inch length.

15. Cut a 45 degree miter on one end of each edging piece. Carefully measure the size of the plywood top and transfer these measurements to the edging pieces using a pencil and a combination square. Cut edging using table saw, miter gauge and stop blocks. Check correct length by over cutting a little and then making very small cuts. Do not undercut.

16. Attach edging to the plywood. (Use bar clamps or pocket screws and glue)

17. Router top outside edge of the top to match the legs.

18. Sand where needed. 19. Attach Top to Base Use a ¾ inch by ¾ inch wood cleat to attach the top. Drill countersink/counterbore holes in the cleat, two holes on two adjacent sides. Screw the cleat to the inside of the frame. Place the top upside down on the workbench, and then place the base on top of it also upside down. Screw the top to the base.

20. Create Lower Shelf Measure the distance from the top inside of the legs to get the size for the ¾ inch plywood shelf. Cut to size.

21. Attach Shelf to Base Cut four ¾ inch by ¾ inch by 18 inch strips to be used as spacers. Turn table upside down and clamp spacers to inside of the legs. Set the shelf on the spacers and screw into the legs.

22. Add a ¼ inch thick by ¾ inch wide edging to the exposed plywood edge of the shelf.

23. Sand where necessary

24. Apply preferred finish.