DIY Network

Legs, Shelf and End Assembly From "Woodworking" episode DIW-201

advertisement

This coffee table -- traditionally not a part of arts and crafts furnishings -- combines the best decorative elements of the era with modern functionality. Biscuits and tenons are used to create durability and strength. In this view of the end assembly, the top portion is the arch and the straight horizontal portion is the stretcher. A plywood arch template helps create a consistent arch for all aprons on the table. Football-shaped wedges -- called biscuits -- help join boards together and create greater strength than using glue alone. A biscuit jointer can be especially helpful to those who engage in a lot of woodworking or who frequently undertake intermediate or advanced projects. Because it easily cuts half of a biscuit shape inside the wood, it can be a worthwhile investment. Bar clamps are a necessary part of any woodworking project. They help glue adhere properly by compressing pieces together with adhesive material to create tight bonds.  REAL VIDEO To insure even greater stability -- beyond that offered by biscuits -- a loose tenon system is used to adjoin the frame's corners. < Click on the Real Player button to see Bruce Johnson create a loose tenon system.

DIY Woodworking host Bruce Johnson demonstrates how special methods -- biscuits and loose tenon joints -- can strengthen the corners, joints and supports of this intermediate-level woodworking project.

Johnson estimates that all materials should cost less than $150.

Note: Project plans may be viewed with

Materials:

Wood for legs (to be cut into 4 pieces, each 2" x 2" x 17")
Wood for stretchers (2 pieces, each 2-1/4" x 19-1/2")
Wood for aprons (2 pieces cut to 3-1/2" x 19-1/2")
Wood for shelf (either 2 pieces of 14-1/2" x 39-1/4" or 2 pieces 7-1/4" x 39-1/4")
Wood glue
Foam brushes
Bar clamps of varying sizes
Ear and eye protection
Pencil
Tape measure
Electric table saw and joiner
Coping, saber or table saw
Belt or stationary sander
Biscuit joiners
Drill with 3/8" bit
Loose tenons
Loose tenons jig

Creating the Legs

A solid piece of wood can be cut and planed to the leg's final dimensions, but gluing pieces together can work just as well to create necessary strength.

1. Use foam brush to glue two pieces of wood together.

2. Trim length to 17".

3. Plane width to 2" x 2".

4. Use small clamps to clamp wood together and allow to dry for at least 4 to 6 hours.

Beginning the End Assembly

1. A stretcher -- also called a rung -- is a straight, short piece of wood used to brace the legs (the addition of arches also helps to brace legs). Cut a piece of wood for each end 2-3/4" wide x 19" long.

2. Next, use thin plywood to measure and cut an arched template. An additional template can also be created for the longer, arched aprons that will appear on the front and back of the table.

3. Place the template on wood (Johnson uses oak), aligning the straight edge with the top of the wood. Trace curved edge with pencil directly onto wood that will be cut.

4. Use coping, saber or band saw to carefully cut the arch.

5. Sand away any marks on edge (Johnson suggests a belt or stationary sander, if available).

Creating the Shelf

A magazine shelf is created by joining several pieces of wood (a full-sized board can be used, but it can often cup -- or sway -- from additional weight on the center). Instead of simply gluing pieces, Johnson uses biscuits to give the piece extra weight.

1. First, cut length of both boards to desired dimensions. Cut and plane width as necessary.

2. Next, align boards and make pencil marks on edges of both boards where the biscuits will join the two. Make first marks about 4" from the end and allow roughly 10" between the additional marks.

3. Once all marks have been made, use a biscuit jointer set to cut half of a football-shaped slot on the inner (joining) sides of each board, near the center of each board's height.

4. Apply glue down sides of each board, in all slots, and on all biscuits.

5. Put biscuits into all slots on one board and align boards. Pull boards together so that slots and biscuits connect.

6. Apply pressure with bar clamp to facilitate bonding. (If enough glue is applied, it will ooze out and need to be removed.)

7. Allow shelf to dry 4 to 6 hours.

Loose Tenon System and End Assembly

The use of loose tenons is a familiar characteristic of arts and crafts furniture. The tenons -- like biscuits -- are used to provide additional strength to corners and joints. Using a tenon jig, a series of holes are drilled in the legs and apron.

1. With pencil, mark area where tenon will be placed.

2. Next, place wood in vise. Set tenon jig at position A and place over pencil mark. Use vise screws to tighten jig into place.

3. Use electric drill with 3/8" bit to drill hole about 1" deep. Repeat for remaining holes on tenon jig.

4. Loosen jig and reset for position B. Using jig as a guide, drill two more holes.

5. Loosen jig and remove from wood. Remove wood from vise and brush away sawdust and chips.

6. Apply glue to each slot and half of each tenon.

7. Tap tenon halfway into each slot, leaving the other half exposed. Repeat for all legs.

8. Place aprons on tenon and repeat for other sides.

9. Once all loose tenon joints have been completed, use long clamps to pull entire end assembly together and allow to dry.

Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!

RESOURCES :
Arts and Crafts Woodworking Projects: 11 New Designs in the Stickley Tradition
Model: 0811726622
Author: Robert E. Belke

Arts and Crafts Furniture: Projects You Can Build for the Home
Model: 094193649X
Author: Blair Howard

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