Once I had all the pieces in final form, it was time to sand everything down and assemble. Everything was sanded down to 220.
First, the skirt and leg pieces. Since the corner brackets I ordered from Rockler called for 1 3/4” square legs, and I had 1 1/2” square, I had to make my own corner brackets. That was simple enough, but gluing up was a challenge. I chamfered the top 3” on the inside corner of each leg. That allowed a lag bolt to be screwed in and then a hole drilled opposite in my homemade corner brackets. Since I wanted the legs to fit tightly to the skirt, I placed a washer between the leg and the bracket and then fastened the assembly down with a wing nut. That allowed me to glue the corner brackets to the skirt pieces, while allowing the legs to be removable.
I could then detach the legs and do the longer skirt pieces, keeping everything square and easy peasy.
Once the bottom was done, I detached the legs and got the skirt lined up with the top. I had to place a spacer to force out the front skirt piece (It wasn’t quite straight). I decided to forgo the tabletop fasteners (risky, I know) and just use glue blocks instead. I glued them to both the top and skirt and added a couple screws to each into the top. That way, at least if the skirt separates from the glue blocks, it will stay in place. I also reinforced the corner brackets with a couple screws.
I wanted to go for a nice, traditional maple finish—and what does that mean? Blonde shellac. It gave a little bit of tone back to the wood and made the boards in the top more even. I had to spend some extra time doing this, as it tended to run a little. I don’t have any pictures of the finishing steps, but you’ll see the final product when I post the project entry.
At the advice of others, I thinned the shellac to about 1pt alcohol, 1pt shellac. I tended to get a lot of drips. I tried using cloths, foam brushes, and bristle brushes, eventually settling on bristled brushes. Anyone have any tips on applying shellac? I revisited The Wood Whisper’s video on shellac and, following his steps, didn’t really improve the application results. In the end, extra care (moreso than say—poly) made the difference for me.
-- Dan, Rochester, NY