1 Create the legs.
a. For each (01) leg, mark one face A. Rotate the part 90 degrees to your left, and mark that face B.
b. Following Figure 1, lay out and cut the tapers on the (01) legs. Go online to LowesCreativeIdeas.com/Woodworkers to find plans for a tapering jig.
c. Drill holes at the top of each (01) leg on the two tapered faces. See the top cross section diagram for hole placements.
2 Attach the apron.
a. Miter cut the (02) aprons to length. Note: These parts are ripped from a 1 x 6.
b. Using glue and pocket hole screws, attach the (02) aprons to the (01) legs as shown in Figure 2.
c. Check the assembly for square, and add temporary bracing on the bottom of the (02) aprons if needed.
3 Attach the sub top.
a. Cut a 1-inch radius on each corner of the (03) sub top.
b. Mark a centerline on the (03) sub top in both directions, and cut out a 28 1/2-inch square from the center.
c. Using glue and nails, attach the (03) sub top to the leg/apron assembly as shown in Figure 3.
d. Scribe a line 3/4 inch from the inside edge around the perimeter of the square opening.
e. Tape off the 3/4-inch portion around the opening using masking tape, and then apply spray adhesive to the (03) sub top.
f. Cut and apply strips of felt to the untaped portion of the (03) sub top as shown in Figure 3, and then remove the masking tape.
4 Build and attach the top assembly.
a. Miter cut and assemble the four (04) edging parts using glue and pocket hole screws.
b. Position the (04) edging assembly 3/4 inch from the inside edges of the square opening as shown in Figure 4, and attach to the (03) sub top using glue and nails.
c. Cut a 2 1/2-inch radius on each corner of the (04) edging assembly.
d. Use a router fitted with an ogee bit to rout the outer edges of the (04) edging assembly.
e. Measure the inside dimensions of the (04) edging assembly, and then subtract 1/8 inch. This determines the length of the (05) banding.
f. Miter cut, long point to long point, the (05) banding to the length determined in Step 4e. Note: These parts are ripped from a 1 x 6. The 13/16-inch dimension listed in the Cut List is the width of the (05) banding.
g. Cut the (06) top equal to the short point to short point length of the (05) banding pieces.
h. Attach the (05) banding to the (06) top aligning it with the better face of the plywood.
i. Cut a piece of felt 6 inches larger than the top assembly, and iron out any wrinkles.
j. Cover the top and outside edges of the (05) banding with masking tape.
k. Apply spray adhesive to the bottom face of the (06) top.
l. Lightly place the felt centered on the top assembly, and iron the felt in place using a slightly warm setting working from the center to the edges.
m. Trim the felt with a utility knife.
5 Apply finishing touches.
a. Fill all nail holes, sand, and apply stain as desired. Paint the outer edge of the (03) sub top black as shown in the top cross section diagram.
b. Allow the stain to dry, and then apply polyurethane.
c. Attach nail-on furniture glides to the bottoms of the (01) legs.
|legs||3 x 3||2 1/2 x 2 1/2 x 27 1/2||4|
|aprons||1 x 6||3/4 x 2 1/2 x 30||4|
|sub top||plywood||3/4 x 37 x 37||1|
|edging||1 x 6||3/4 x 5 x 40||4|
|banding||1 x 6||3/4 x 13/16 x 29 7/8||4|
|top||plywood||3/4 x 28 3/8 x 28 3/8||1|