1. 6/4 walnut, at least 7" wide
1. Small scrap of plywood at least 5" W x 5" H x 1/2" T
2. PVA glue (I used Titebond II)
3. 4x 3/4" #8 screws
4. 1/4" x 3/4" cutter
5. 1/4" x 1 1/2" cutter
6. Formby's Tung Oil
1. Jointer, planer, drum sander
2. 1/2" roundover bit
3. 5/8" roundover bit
4. 1/2" router (I used a Festool OF 1400)
5. Vertical workstation
6. 1/2" drill bit
7. Flush cut saw
8. Random Orbital Sander (I used a Festool ETS 150)
9. Sand paper in grits 80, 120, 160, 220, 320, 400
Top:
- Glue up a tabletop at least 27" W x 22" D x 1 1/4" T
- Make the inside cuts first in 1/4" passes with 0.03" offset, finishing at full depth with 0" offset.
- Make the outside cuts in 1/4" passes with 0.03" offset, finishing at full depth with 0" offset.
- Fill any voids with epoxy and sand using a drum sander and random orbital sander to 120 grit.
- Use a 5/8 roundover bit to round over the bottom edges.
Angle guide:
- Cut the Angle guide using at least 1/2" plywood.
- First perform any inside cuts (using helix) before outside cuts.
Legs:
- Obtain two boards at least 7" W x 32" H x 1 1/4" T
- Place two copies of leg-face, and make the outside cuts. Use 1/4" passes with 0.03" offset, finishing at full depth with 0" offset.
- Repeat for the second board.
Leg tops:
- Using the vertical workstation and angle guide you cut previously, cut the tenons in all 4 legs.
- Use 1/4" passes with 0.03" offset, finishing at 1 1/4" with a 0.007" offset. Reduce this offset by 0.001" until it fits snugly (with room for glue) in the table top.
Legs:
- Roundover the front side of the legs with a 1/2" roundover bit.
Shelf:
- Cut two shelf-fronts, and two shelf-sides using the same settings as above.
- Flipping the shelf-sides around, place the shelf-side_holes using a grid, and helix the included holes to 1/4" inch.
- Glue the shelf-sides and shelf-fronts together, making sure to insert the hollow brass tubes cut to appropriate size.
- Roundover the sides of the shelf using a 1/2" roundover bit.
Assembly:
- At approx 6", glue and screw the legs to the shelf-sides. You'll want to drill a countersink first to 1/2" using the 1/2" drill bit.
Dowel plugs:
- Using scrap walnut, cut 1/2" dowels using the on-tool Circle, and dial the fit by starting 0.003" undersized and creeping up to a snug fit with glue in 0.001" increments.
- Fit the dowel plugs in the countersinks with some glue, and cut flush once dry.
Assembly:
- Glue the top mortise and tenons together.
- Sand to 400 grit.
- Apply finish (I used Formby's Tung Oil)