Pie Crust Table #6: The top is finally done!

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Blog entry by GaryK posted 05-10-2009 09:56 PM 2511 reads 1 time favorited 24 comments Add to Favorites Watch
« Part 5: The edge completed! Part 6 of Pie Crust Table series Part 7: The column »

I guess I used this step as a lesson to myself on how to remove a lot of material fast. Having never done anything like this before I thought I would try different methods.

The first method was route channels leaving some uncut material to support the router and then use my flush cut saw to remove them. Then I thought of all the dust that would make so I tried to make a bunch of saw cuts and beat them out with a hammer. This worked very well at limiting the amount of chips.

But when I used the router I was scared to death of slipping near the and ruining the entire thing.

Then I tried to use a stationary router in moving jig. This is the jig that I used to flatten my work bench.
But once again I was afraid when I got to the ends because I was cutting blind.

This is the method I ended up using. A stationary jig with moving router. It was very effective and relatively fast.

I made it with hardwood sides the keep it from drooping in the middle and melamine to reduce friction. Another thing I did for safety was to install stops. One on each end to limit the travel of the router and in the lower picture to keep the jig in position.

I just lined it up in the center and made a cut and then rotated the jig around the center point looking through the slot to position it. I also used an old candle to wax the bottom and edges or the router to make it slide very easily.


The slot was about 2” wide allowing me to make two passes, with the 1 1/2” bottoming bit I used, before re-positioning the jig. One half a rotation of the jig and I was done with the first pass. I took about 1/4” of material off at a time.

It ended up taking me about 1/2 an hour of cutting to complete it.

After a little sanding with 40 grit

And Last but not least 1/2 of the pile of wood removed with router. That’s an 18” scale.

Next time I will start with the stand. Like I said in the beginning it will be something different.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

24 comments so far

View cobra5's profile


154 posts in 3007 days

#1 posted 05-10-2009 10:12 PM

thanks for the inspirations,

-- tool time tim aka "cobra5"

View Rj's profile


1047 posts in 2668 days

#2 posted 05-10-2009 10:14 PM

Wow Gary That looks great! it will be exciting to see it when your finished .

Thanks again for filling us in on the process . (I’m learning alot from your posts)

-- Rj's Woodworks,San Jose & Weed Ca,

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 3337 days

#3 posted 05-10-2009 10:15 PM

That’s sure going to be a beautiful table.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View a1Jim's profile


113725 posts in 2614 days

#4 posted 05-10-2009 10:15 PM

Very nice Gary looking forward to more progress

-- Custom furniture

View lew's profile


10620 posts in 2792 days

#5 posted 05-10-2009 10:22 PM


Thanks for sharing the trip to what is going to be one beautiful table!!


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View tenontim's profile


2131 posts in 2781 days

#6 posted 05-10-2009 10:31 PM

This has been a very informative series, Gary. I can’t ever see myself making this style of table, but the methods that you used are very interesting. Hopefully they’re filed away in the brain bank and can be retreived at a later date. Thanks for all of the post on this.

View Scott Bryan's profile

Scott Bryan

27251 posts in 2859 days

#7 posted 05-10-2009 10:33 PM

Your ingenuity and resourcefulness never ceases to surprise me. Many of us, I know I would fit in that category, would have settled on a removal technique at the start of the process and doggedly stuck with it rather than stopping midstream to evaluate things and try to come up with a more effective process. And building a jig in the middle of things!!! That interruption only slows you down- right?

Nice job, Gary. Thanks for the post.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View pommy's profile


1697 posts in 2728 days

#8 posted 05-10-2009 10:51 PM

as always gary you look at the bigger picture i was talking to fellow lumberjock on saturday ( philip edwards )at a local wood show
and i told him how wonderfull i think your work is thank you for show us mear mortals how to do things properly


-- cut it saw it scrap it SKPE: ANDREW.CARTER69

View DocK16's profile


1162 posts in 3124 days

#9 posted 05-10-2009 10:57 PM

I have been waiting for each episode to be posted since you announced the project. Several good ideas to hog out the waste but the final method I think is the best. Can’t wait to see the base I’m sure you won’t disappoint.

-- Common sense is so rare anymore when you do see it, it looks like pure genius.

View Napaman's profile


5435 posts in 3114 days

#10 posted 05-10-2009 11:11 PM

wow…that is amazing…you said half an hour—-for all methods??? that seems fast…amazing..

-- Matt--Proud LJ since 2007

View Joe Lyddon's profile

Joe Lyddon

8438 posts in 3089 days

#11 posted 05-10-2009 11:33 PM

Hi Gary,

Very good progress!

I’ve gotta say… when I saw that circular saw cutting slits, my first thought was “Oh No!”... I was happy to see how you modified your method.

Your final solution is very similar to a fixture I made called Router Skiis. For the average project, it works pretty well.
See more about it at…

Your Top really turned out GREAT! Thank you for the progress reports!

Now, for the part that holds it up! :)

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View SCOTSMAN's profile


5782 posts in 2622 days

#12 posted 05-10-2009 11:40 PM

Great Job as usual gary well done laddie Alistair

-- excuse my typing as I have a form of parkinsons disease

View Karson's profile


34986 posts in 3438 days

#13 posted 05-10-2009 11:42 PM

Can you take the chips back gary and ask for your money back. Tell them it was not needed.

Great job on the flattening. and removing.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Lee A. Jesberger's profile

Lee A. Jesberger

6790 posts in 3017 days

#14 posted 05-11-2009 12:14 AM

Hi Gary;

I’ve been watching with interest in how you did the top. As usual, your work is Masterful.

Hollowing out the center is a scary process, huh?

A suggestion if you don’t mind. If you are going for an 18th century look, the outside or “crust” looks a little on the bulky side.

That has a lot to do with our decision to carve the edges, when we were building one:

Great work!


-- by Lee A. Jesberger

View CanadianWoodChuck's profile


400 posts in 2951 days

#15 posted 05-11-2009 12:24 AM

Excellent progress report Gary – it will be beautiful. I love your flattening jig. Thanks

-- Wood Chuck (Bruce)

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