Round Table Top

 

My friend Robert had a project to make a round table top...roughly 48 inch diameter. 
He wanted to re-purpose some old yellow pine.


Wood Selection

Blank Milling

Joinery Milling, Domino Work

Glue up

Trammel Jig Saw Cut

Finish Milling


 

Wood Selection

The wood for this project was reclaimed from a 70 year old plus home.
It was a kitchen counter...roughly 24 inches by 12 feet.
It had been cut at 7 and 5 feet to transport.  Robert and I cut the pieces to be blanks about 60 inches long.  This was done with track saw.  Blanks were ripped along the glue lines of the original construction.
Blanks were then moved to shop and rough assessments were made as to which board would go where, problem shifts, etc.
The image to the right is the bottom side of the 4 blanks.
This shows the tight grain of the yellow pine.
This is the contrast between a surfaced underside and the top side of a blank.


Blank Milling

 

After assessing all of the blanks, they were crosscut to ~50 inches with track saw.

Here are the undersides of the four blanks.
Using the better top sides as the reference faces, the bottoms were surfaced a couple of runs through the planer.
Then they were flipped and the top sides were surface planed.


Example of a couple of surfaced blanks.
Then the show face was put to the fence and an edge was jointed.
Then the jointed edge was put to the table saw fence and the other edge was ripped.
Here are the milled blanks.
Although they were truly milled 4 square, because they were too wide to surface on the jointer, they turned out pretty nice.
This is because the pieces were quite stable...no wonky pieces.
The blanks were then run through the drum sander a couple of times.
This made the pieces look great, but we had problems because the sandpaper got clogged quickly due to the nature of the pine resin in our blanks (and the width of the blank was an issue also). 
We had to give that up...plus we had to mend a couple of snipes using hand sander.

Joinery Milling and Domino Work


After the blanks were all surfaced, we looked for any flaws to circumvent...and then we made the layouts for the Domino floating tenons.



The Domino work was done at the MFT3 table...we used 5 x 30 mm Domino tenons...the mortises were cut on middle loose setting...4 mortise-tenon joints per edge.
Mortises were cut slightly above center line to be closer to show surface.

Glue Up
The mortise-tenons were dry fit...and we did a walk through on clamp location.
We glued the two outer pairs first and then joined those two pairs...had decent squeeze.
Glue lines looked pretty good...cleaned up with Nishiki kinari paring chisels.

Finish sanding 150mm sander...grits...
Assessing the blank...used straight edges to test flatness of the big slab...looked really good
 Also checked with winding sticks...all boards looked really flat and square.
Trammel Jig Saw Cut

Flipped the blank over and cleaned up the underside.  With the exceptions of some wood flaws, the underneath appearance was great.
The trammel system will be secured and the layout and cutting will all be referenced from the bottom face.

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We laid out the circle with a trammel.
Then we set up the trammel accessory for the Carvex jig saw.
Drilled the 11/64 trammel point hole deep enough for the point to really be tapped in and secure.
Set the guide so blade would cut our circle on inside edge.
Using the Festool trammel accessory became a horrific process...the base shoe of the jig saw was precarious and when pitch build up became an issue there was a torque twist that cut wonky.
We stopped that tool setup.We redrew the circle.
 Decided to use the Bosch to free cut the circle.
Cut was really slow...had to clean the blade every ~20 inches...major resin build up...cleaned and doused in acetone helped ...overheating was an issue, went through three blades...but I was pleased at the performance of the  Freud Diablo Top & Bottom Cut blades.  For such hard wood, these "fine finish" blades did a great job.
In every aspect of this project, the resin build up was difficult as soon as the tool warmed up...


Final Milling
After the blank was round...used heavy duty 1/2 inch shank Amana round over bit to break the edge on up and down sides...had to clean often.
Top and bottom edges routed...
Hand sanded...

Legs...
Finish application...

 

 

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