LAMINATING THE LEGS
When I left off I had cut most of the strips. That was a very tedious job and I broke it up over several days (over 80 total).
I finally got to the point where I could start bending my laminations. Here is the “dry” trial run:
Here are the strips laid out to apply the glue. I had to mix the special glue made for laminations:
And here is the first glued up leg in the form:
After about three days I had all eight legs. Some of them are still wrapped in the plastic that keeps them from sticking to the form:
My gluing form doubled as a jig for positioning the legs on my Radial Arm Saw bench to trim the ends. This ensures that each leg is exactly the same height and the feet are flat on the floor.
I ran them through the planer to clean up the faces:
Then I used my spindle sander to clean up the sides:
The “Octagon” is the structure underneath the tabletop that the legs attach to.
I set my saw to the magic number 22.5 deg to cut the eight sides. It came out perfectly the first time, I guess I got lucky.
Then I set up my “tenon sled” on the tablesaw with a single dado blade and cut the slots for the keys:
I planed some maple stock to make the keys:
And cut them to length:
Here is the Octagon all glued up:
This thickness sander is new to my shop and this is the first time I had a chance to really use it. It worked great for cleaning up glue and truing the top and bottom of the Octagon.
My first sneak peak at the base of the table!
The joint between the legs and the Octagon needs to be very strong, since they are only connected in one place. So I plan on cutting a curved slot on each side of the Octagon to accept each leg.
I made a pattern/jig for my router to rout out the channels. This allowed each channel to be in exactly the same location and same angle so I don’t have a wobbly table:
Here is the leg set into the channel:
The finished Octagon with leg channels:
The legs glued and clamped to the Octagon… I plan on adding either dowels or screws to each joint for extra reinforcement later:
I couldn’t resist…
Now All I need to do is make the bent-lamination Oval-shaped apron, and dye/finish the table top.
About 19.5 more hours. Total building time so far: 28.5 hours
-- Happy woodworking! http://www.blakeweber.us