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.