Built entirely from discarded materials, this tabletop is made using an old 15-lite door with the glass removed and replaced with kauri pine flooring as the infill.
Step 1: Prepare the Door
Step 2: Secure the Backing
Step 3: Position the Infills
Step 4: Prepare the Rails
Step 5: Make the Dowel Joints
Step 6: Assemble the Frame
Step 7: Add the Corner Bracing
Step 8: Attach the Tabletop
Step 9: Attach the Trim
Step 10: Smooth and Finish
Notch corners in the underpanel to allow for the legs. Put the backing in the panels, apply adhesive and secure the underpanel to the door with 1-in. screws. From the top, secure 1-in. screws through the backing to pull up the underpanel.
Generously apply construction adhesive on the backing then secure three infill pieces in each panel. Core out and square up the lock and handle holes with a sharp chisel and cut matching infill pieces to fit, securing with adhesive.
At the base of the end and side rails mark 3 1/2-in. from the ends and 3 1/2-in. from the top, joining with a curved line, using a circular saw and jigsaw to cut and a belt sander to smooth the outer surfaces of the rails.
At the top of the legs and end of the rails, use a doweling jig to drill three 3/8-in. holes 1 3/8-in. apart. Do a test fit and adjust if necessary, apply wood glue in the holes and on the end grain of the rails, assembling with dowels.
Tap the legs and rails together with a mallet then position wood corner blocks at the outside corners to hold the frame and set up a long ratchet cargo strap to pull the frame tightly and leave to dry. Check legs are plumb and square.
Position the corner braces 3/8-in. from the top of the legs to allow for the underpanel, securing with #8 x 3-in. screws into the legs and #8 x 2-in. screws into the rails.
To secure the tabletop to the frame, position one cleat on each end and three on each side by drilling two pilot holes into the rails and two clearance holes into the tabletop, securing with screws.
Miter the trim, drill pilot holes then secure it to the tabletop with 1 5/8-in. screws, filling the screw heads with wood filler. Hand plane the infill pieces level then smooth with a belt sander using coarse sandpaper then a random orbital sander.
Fill gaps between the infill with polyester resin and leave to dry; then, smooth with 120-grit sandpaper. Apply three coats of French polish over the tabletop, lightly rubbing between coats with steel wool. Finish with a coat of beeswax polish.
© 2012 Reiman Media Group, LLC.