Upping the game with a new card table! #3: The demilunes

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Blog entry by Builder_Bob posted 05-09-2010 05:10 PM 1714 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 2: Gluing up the apron sections.. Part 3 of Upping the game with a new card table! series no next part

Time to make the table top. Two tops actually, each a half circle. Two demilunes (half-moons). They fold together for a nice demilune wall table and swing into a full circle when the piece is converted into a game table.

Picking out the mahogany boards.

Board Buddies, don’t saw anything without them.

Throw them a few biscuits for good measure. Notice the oddly colored board on the far right. This board would become my nemesis.

I tried the “tape over the joints” trick to prevent glue pickup on the boards.

In this shot, I placed the tape directly over the joint of the clamped boards and cut through the tape with a blade. Then I separated the boards and glued them up. It worked well, but I had (and still have) some blue tape that got pushed into joint.

For the other half, I put the tape as close to the edge as I could. No more tape glued into in the joint, but I had some glue pickup near the joint line. All in all it did help, and I’d do it again.

Here is the do-it-yourself router jig to cut out the half circles. It’s made from scraps of this and that hot glued together. The pivot for a half circle would be right at the center of the straight edge.

This little fixture establishes a pivot point at the edge of the board.

I like to make several passes with the router, cutting a little deeper on each pass. When I get close to breakthrough, I run a jigsaw through the channel. cutting off the waste. Then its out with those cookies to trim the edge with a flush cutting bit. Doing the job in small steps lowers the anxiety level a lot.

When the two tops are ready they can be clamped back to back to make a full circle. This allows the routing of a decorative edge without worrying about breakout.

Since one of the tops flips over when used as a game table, I chose a simple symmetrical shape for the edge.

See that furry cut on the right? That’s that oddly colored board. Everyone says that African Mahogany is difficult to work because it leaves stringy and furry stuff behind. I’ve never had trouble with mahogany doing that until this board entered my shop!

-- "The unexpected, when it happens, generally happens when you least expect it."

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