Building a table is one of the most deceptively simple woodworking projects going. What could be easier than gluing up a few boards and applying a finish, right? But reality is often surprising, because building a top for that table can go wrong in ways you might not realize until it’s too late. Here are my favourite tabletop construction tips, plus advice on how to avoid trouble.
Begin by cutting off a 10-in. length of the board and setting it aside. Rip the remaining 38-in. board to 6 in. wide and cut five evenly spaced saw kerfs 5/8 in. deep along one face. Crosscut the slotted board into four 9-in. pieces and glue them into a block, being careful not to slop glue into the saw kerfs (you can clean them out with a knife before the glue dries). Saw a 15-degree angle on one end and screw the plywood piece under the angled end of the block.
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Luckily, we have also managed to find a detailed video tutorial of the Barn door project that illustrates the process of building a Barn door of your own. The steps and instructions in the video tutorial are different from the source links listed above. Actually, you can make different types of designs for your Barn door depending on which one you can afford easily and DIY on your own.
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If you’re like me, every time you wander through a big-box furniture store, you feel a little insulted. Here you are, a man, staring at relatively simple furniture, being asked to lay down large sums of money for a bookshelf, dining set, or desk. And if you know enough about wood to spot laminate and fiberboard, you’ll quickly see these expensive pieces of furniture have a shelf life (no pun intended) of about two years.
This DIY has a bit of a backstory: In my basement workshop—as a byproduct of about a half dozen previous projects—I’d managed to accumulate a small mountain of scrap wood. Though the pieces varied in size, most were 2×4 boards. For weeks, I pondered the question of how to use them. There wasn’t enough material to build anything substantial, but at the same time, this was much more wood than I would feel comfortable chucking or committing to kindling. I suddenly seized on the idea of turning those leftover boards into a rustic tabletop, but then I let the project momentum slow to a creep, and in the blink of an eye another few weeks had gone zooming by. Things finally came to a head one day when I was scanning the local giveaway listings. There, I discovered that one of my neighbors was trying to get rid of an old metal garden table. Upon seeing the pictures, I knew immediately that this would be a great table to top with the scrap wood surface I’d been planning to make with all those 2x4s!
Leave your tabletop longer than necessary until the sanding is done, then cut to final length. Most tabletops are too wide to trim on a tablesaw, even with a crosscut sled, and this is where I use a hand-held circular saw. Clamp a guide strip so it’s square to one edge, then follow it with your saw. Repeat the process on the other end, then carefully use your hand-held belt sander to remove any blade marks on edges. It sounds like a coarse process, but you can get great results this way.
The engineering involved in building this garden bench is pretty simple, and we have provided some links to get a full cut list and plans with photos to help you along the way. Additionally, to the stock lumber, you will need wood screws, barrel locks, and hinges to complete the table. A miter saw or hand saw is also extremely helpful for cutting down your stock to the correct angle and length.
Drill four 5/8-in.-dia. 1/2-in.-deep holes on the large disc?inside the traced circle?then use 5/8-in. dowel centers to transfer the hole locations to the underside of the small disc. Drill four 1/2-in.-deep holes on the underside of the small disc and a 1/2-in.-deep hole in the center of the top for the dowel handle. Glue in the dowels to join the discs, and glue in the handle. We drilled a wood ball for a handle knob, but a screw-on ceramic knob also provides a comfortable, attractive grip.
Finding a toolbox for a mechanic, for his hand tools, is not a big challenge at all - there are dozens of the tool boxes available on the market, from huge roll-around shop cases to small metal boxes. Plumbers, electricians, and farmers are well served, too, with everything from pickup-truck storage to toolboxes and belts. But, if you are a shop-bound woodworker then the case changes. You get to need a tool box that suits the range and variety of hand tools that most woodworkers like to have. For those who deny making do with second best, there's only one solution, you’ve to build a wooden toolbox that should be designed expressly for a woodworking shop.
Be sure wood is dry. Material from a job site or floor joists that existed in a crawlspace may have high moisture content; material from a conditioned space should be dry. Wood can be dried in a kiln (ask your local lumber mill) or stored inside through the winter. If time does not permit, stack wood in a hot dry place with 1" spacers between layers. Allow to dry for a minimum of two weeks.
We no longer have that problem because we picked up a set of Mag Shims from FastCap. Mag Shims are 1/8-in. magnetic spacers. If you need a blade height of 7/8 in., simply stack seven spacers, and raise the blade to match. They also work great for setting the depth on router bits and drill presses. We stick them right to the backside of the fence, so they’re always at hand and never get lost.
An assortment of chisels should be part of every workbench. Chisels are not just for wood carvers. Any woodworker will need chisels to clean out joints and saw cuts. Look for chisels made of high-alloy carbon steel or chromium-vanadium alloyed steel. Hardwood grips are best, especially if they have metal caps on them. This will keep the end of the handle from becoming malformed when you hammer on it.