serving tray for a long coffee table in front of a couch.

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Blog entry by hobby1 posted 06-28-2013 03:17 AM 1822 reads 1 time favorited 8 comments Add to Favorites Watch

I’m starting on another serving tray, this one is around 3ft. in length and a width of around 12in.
I am going to laminate aluminum flashing on some masonite board for the bottom, and place aluminum tubing over dowels for the handle bars.

The rest of the unit is made from walnut sticks 1in.x1in. scrap, and some walnut cutoffs for the handles and feet brackets.

I started out by sizing the walnut frame pieces, and doing the miters, to make a frame.
The frame pieces are also rabbeted to recieve the bottom laminated panel.
Also the assembly will be with glue and dowel tenons.

Then I drew out a handle bracket, on one workpiece.

I want it to be angled back,so I set the board on edge of the frame, that gave a good angle to work with.

Now I scribed a veretical and horizontal square line to cut out for a notch.

And proceeded to cut the straight portions of the notch with my’ blade runner’ saw.
This showes the process as a mock up after I already had the notch cut out.

Test fit the workpiece.

Now cut out the curvature profile on my small bandsaw.

all four handle brackets ready for profile sanding.

Now time to drill for dowel tenoning of the frame to attach the handle brackets.

In my opinion, this is the best doweling jig I own, a ‘dowel center, and a brad point bit, outfitted with a stop collar, to allow me to finish the hole flush and square.

I couldn’t use the stop collar here due to lack up space.
I really like my workmate for clamping stock to machine workpieces.

and the dowel tenon installed

all four handle brackets fitted nicely, only dryfitted at the moment, need to do more machining to them.

The profile routing on the frame and handle brkts.

Dryfitting of hndl.brkts. to the frame.

The begining of the bracket feet, I found a nice profile on the innernet, that I will use, to make a set of feet, but right now I need to do all the machining of the feet blanks.

Top profile roundover

And to my table saw to cutt out the rabbet, to recieve the frame.

After cutting out the four sets of bracket feet blanks..

Next I’ll drill for dowel tenoning then cut out the profiles for the bracket feet.

Have fun in the shop.

8 comments so far

View stefang's profile


15881 posts in 3334 days

#1 posted 06-28-2013 08:19 AM

Good progress so far. I’m looking forward to seeing the finished product.

-- Mike, an American living in Norway.

View Gibernak's profile


124 posts in 1846 days

#2 posted 06-28-2013 01:41 PM

Yes I’m also looking forward to the next part. Nice work.

View hobby1's profile


335 posts in 2297 days

#3 posted 06-28-2013 07:12 PM

Thankyou gentlemen for the nice complements.

Here is this afternoons progress.

The dowel tenoning for the feet brkt. blanks.
I tried to keep the dowels inward as close as possible, so they won’t intefere when I cut the profile out on the blanks.

Here is a quick drawing of the foot brkt. I’ll use this as the pattern.

And now the work blanks marked out and profiled,

now these need roundover on there edges,

the before and after shot of the dremel contouring of the edges.

but the contouring is to small to get a router bit and bearing into, so I used my dremel and the smallest drum sander in my kit, to round over the edges.

and the before and after shot of a assembled foot bracket, after detail sanding, the entire workpiece.

Now to install the foot brkts. I need to remove part of the handle brkt.
So I will mark off where this needs to be cut, however because the handle brkt. is at a slight angle, around 13deg. I need to set my miter guage to that angle and cut this workpiece on my blade runner saw.

so the foot brkt. can fit flush to the main frame, and fit nicely under the handle brkt.

Here the handle brkt.sticks out too far from the main assembly,

so some roundover sanding on my disc sander to knock the corner edge off.

Now I can permanently glue the foot brkts. on the the main frame.

To work on the bottom panel, here the masonite is cut to size,

Apply contact cement to both the masonite, and aluminum flashing.,

the carcass all glued up and ready to recieve the laminated panel.

And the laminating process,

The result at this stage in the build.

Next I need to work on assembling the handle bars themselves, as well as any decorative scroll work to attach to the main frame.

Have fun in the shop…

View hobby1's profile


335 posts in 2297 days

#4 posted 06-29-2013 06:11 PM

Using my turbo cad, I drew up a floral leaf pattern, and printed it out, for a cutting pattern.

I need a total length of 29-3/4 in., my scroll saw has a 16 in. throat capacity, so I cut the workpieces into 4 equal parts, and paired them up and temporary held the pairs together with small brads on each end, and filed any nail protruding the other side to keep from scratching the table top of my saw.

after the scrolling is done,

and where they will go on the main frame,

later I will use decorative brass pins I found, for the center of the floral cutout, so I need to drill a hole to prevent any wood splitting.

now I can glue the scrolling details onto the mainframe.

and the details up close.

and the progress to date.

have a nice day.

View hobby1's profile


335 posts in 2297 days

#5 posted 06-29-2013 11:21 PM

This afternoon I made and applied a interior trim around the inside panel to cover the edge joints of the panel to frame,

then I placed in the brass colored nails into the floral pattern,

and that is far as I will get this week,
next week I’ll start working on the handle bars themselves.

Have a great weekend.

View hobby1's profile


335 posts in 2297 days

#6 posted 07-03-2013 01:11 AM

I didn’t have any aluminum barstock tubing for the handle bars, so I have available some pieces of 3/4” square spalted maple, so these are the handle bars,

I rounded over the edges on my router table, gave them a good sanding and installed them into the handle brackets, so this completes this project.

Thanks for following along everyone

Have a great day.

View Mark Shymanski's profile

Mark Shymanski

5621 posts in 3712 days

#7 posted 07-29-2013 04:17 PM

A great blog, thank you for all the detail and the step by step photos!

-- "Checking for square? What madness is this! The cabinet is square because I will it to be so!" Jeremy Greiner LJ Topic#20953 2011 Feb 2

View hobby1's profile


335 posts in 2297 days

#8 posted 08-09-2013 10:19 PM

Thankyou, I’m glad you enjoyed this build blog.

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