Gaithersburg Woodworking
The Building Process
After a design is confirmed by the clients, I start the process by selecting the wood for the base and the table top.
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The pieces go through an initial first cut (rough cut) which is larger than the finished piece. Table legs are jointed to get one flat face to ensure there is no glue line in the seams.
The table top pieces are laid out to determined the best grain match and then next marked for floating tenon to assist in the joinery
Mortises are then cut to assist in keeping the table top flat while being glued up. I use Festool Dominoes instead of the traditional biscuit or dowel joinery. Dominoes are a hybrid between biscuits and dowels.
The dominoes have a better glue pocket and add some support to the top.
In this case the table top was glued up in sections to ensure that the glue would not dry prematurely.
While the top is being glued together, the start of the base can begin. In this case, pine is jointed and then glued together to make a thicker style leg. Then its jointed (again), planed and then cut to final thickness on the table saw.
After final dimensioning of the table leg parts, the design the clients wants can now be joined together. In this case, the client wanted a half lap style so all the half laps were cut - either by hand or machine and then cleaned up with a chisel.
After a dry fit of the base, then we are ready to glue everything up and add mechanical fasteners (if needed).
Matching benches are constructed in the same fashion. The table tops are cut for mortises, glued and clamped while the bench base receives the same half lap joints.
After the base completed drying and the initial glue up of the table top is dry, our attention can be focus on installing breadboard ends.
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First the table top is squared off. A circular saw and an edge guide can be used; however, I am using a tracksaw in this instance
After the top is squared off, the table and the breadboard end are joined by using floating tenons. All but one slot on the breadboard end is cut on the loose setting so the table top will have room to expand and contract.
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Then a dry fit is done to ensure the proper placement of dowels.
The dowels pin the breadboard to the table, but still leave room for expansion and contraction so the table top will not crack or split during the seasons
The dowels go through the table top and through the tenon, but not the bottom half of the table top. A rasp is used to widen the holes in the tenon so the table can expand and contract.
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After the tenon is widened the dowel can be inserted into the top - the top of the dowel only being glued to the top part of the table. Then the excess dowel is cut off using a flush cut saw.
After the dowel is cut and the table top sites flush and is ready for sanding
The table top can be hand planed if there are any high spots. After everything is sanded with 80, 120, and 220 grit paper or card scraped to ensure a smooth finish.
Sample stains are sent to the client so they can choose the color of their choice.
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After the stain is chosen its then applied and dried. Then three coats of polyurethane are applied sanding with either 220 or 320 in between coats.
