A mini table (or stool) made in Corian and Hickory. Features exposed joinery (through tenons to the edge) that highlight the contrast between the materials used.
Files included (6)
Hickory : 1.5"x1.25" squared stock - minimum 18" per leg. (See drawing for more details)
Corian : 2 X sheets 18" x 13" x 0.47" (12mm)
Epoxy (I used 3M DP-100)
1/4" up-cut bit
1/8" up-cut bit
Before diving into the project, I highly recommend getting familiar with the 3D model (included above is the fusion 360 model). The model is fully parametric (see image) and gives you the ability to customize it to your liking with options for stock size (of each material) and overall dimensions (including angles!) of the stool.
If you would rather just build the project as is, I have included the svg cut files and a 2D drawing that will help with raw stock dimensions.
1. Start with the legs. Prepare stock for legs using dimensions in 2D or from 3D if you are changing parameters. Recommend cutting the angles on the faces (with a miter or table saw) at this point; it makes setup on the vertical workstation easier.
2. Cut the joinery on the top side of the short leg on the vertical workstation (TopLeg_TopTenonsv2). Setup the angle using the top face of the raw stock as reference and place the file using a grid on tool. Cut all 3 legs at this stage.
3. Next cut the tenon on the bottom side of the short leg (TopLeg_BottomTennon.svg). Setup for the stock should be same as the previous step on the vertical workstation.
4. Now move on to the mortise on the bottom leg (BottomLeg_mortise.svg). This can be done on a flat surface as long as you can place tape on the same plane as the leg. Use the on tool offsets to dial in the fit for each of the tenons on the short legs.
5. For the top I laminated 2 sheets (with epoxy) of 12mm corian in order to get the desired thickness. Cut the joinery features for the top in the Corian (TableTop_BottomFace.svg). Note that you are cutting the features from the bottom side so pick your cosmetic face accordingly. Here, you can use on tool offsets to dial in the fit of the through tenons.
6. At this stage I put a 12mm x 45° chamfer on the bottom edge of the table top to match the angle of the short leg. I used a router table with a beefy cutter for this task, but this can also be done with sandpaper and a LOT of patience.
7. Glue up time! First glue each of the legs together at the mortise and tenon. This was failry challenging to clamp so I used some CA (or super glue) in addition to the wood glue to act as a clamp.
8. To assembly the legs to the table top I used epoxy (DP-100 in this case) and clamped around the perimeter of the table with a band clamp.
9. After the glue has adequately setup sand the faces and edge of the hickory and corian flush to your hearts content.
10. Finish the hickory with an oil based finish (I used OSMO) so the grain really pops. Clean up any finish that ends up on the corian before it starts to dry.
11. Done! Your mini table/stool/horizontal surface is ready to use!