COFFEE TABLE/ TV STAND PROJECT 7-12-2011
Our project today is a unique coffee table or TV stand made from poplar squares, dowels and wood buttons. This is a weekend project for the skilled home woodworker. The table dimensions are 36” L x 20” D” x 19” H. We have our factory superintendent, Ron Dennis assisting us with our project today along with help from Amy.
The materials list for this project includes 10 – 1” x 36” Squares, 16 – 1/2" x 48” Dowels, 4 – 7/16” x 48” Dowels, 76 – ½ Wood Buttons and a pc of plexiglass 34” x 18” and ¼” thick.
Tools required are a hammer, glue, hand drill and drill press, tape measure, a 7/16” & 1/2” flat bottom wood drill bit.
Begin drilling the two upper side pcs for the top shelf ( Parts A ).
Take a 1” x 36” Square and mark 3” from each end on center and drill a ½” hole all the way through. From the center of either one of those holes drill 14 identical holes 2” on center. There are 16 – ½” holes on this side.
From that same side drill a 7/16” hole – 1/2” on center from each end. These holes are drilled all the way through. There are 2 – 7/16” holes on that side along with the 16 – ½ “ holes.
Take that same pc and turn it over on it’s side and mark and drill a 7/16” hole – 1 ½” from each end. These two holes are drilled all the way through.
From this same side mark and drill from each end a 7/16” hole – 5/8” deep -- 4” on center. From the center of one of those holes drill 13 identical holes – 2” on center. There are 15 – 7/16” holes on this side.
To cut and drill the lower two side pcs for the top shelf ( Parts B ) take a 1” x 36” Square and cut to 32”. From each end mark and drill a 7/16” hole 5/8” deep – 2” on center.
From the center of one of these holes drill 13 identical holes – 2” on center. There are 15 – 7/16” holes on this side.
Take that same pc and center a 7/16” hole - 1 1/8” deep on both ends.
To cut and drill the 2 upper shelf cross pcs ( Parts C ) take a 1” x 36” Square and cut to 18”. From each end mark and drill a 7/16” hole - 5/8” deep and 4” on center. From the center of one of those holes drill four identical holes 2” on center. There are 6 – 7/16” holes on this side.
Take the same pc and turn over and from each end drill a ½” hole – ¼” deep – 3” on center. From the center of one of those holes drill 5 identical holes 2” on center. There are 7 – ½” holes on this side. These shallow holes are for the wood buttons.
Take that same pc and center a 7/16” hole – 1 1/8” deep on each end.
To cut and drill the two top shelf lower cross pcs ( Parts D ) take a 1” x 36” Square and cut to 20”. From each end mark and drill a 7/16” hole - 5/8” deep – 5” on center.
From the center of one of these holes drill 4 identical holes 2” on center. There are 6 – 7/16” holes on this side.
Take the same piece – turn over and from each end mark and drill a 7/16” hole all the way through – ½” on center.
To cut and drill the two lower shelf side pcs ( Parts E ) take a 1” x 36” Square and cut to 32”.
Mark and drill from each end a ½” hole --- all the way through 2” on center.
From the center of one of those holes drill 13 identical holes 2” on center.
There will be 15 holes on that side.
Center and drill a 7/16” hole – 1 1/8” deep in each end.
To cut and drill the four legs ( Parts F ) take a 1” x 36” Square and cut to 18”.
From one end drill a 7/16” hole all the way through 2” on center. This will be the top end of the leg.
From the other end drill a 7/16” hole all the way through 5 ½” on center.
Center a 7/16” hole – 1 1/8” deep in the top end of the leg.
To cut dowels for the upper and lower table surface (Parts G) take ½” x 48” dowels and cut 31 pcs to 19 ½” in length.
To cut the short decorative support dowels ( Parts H ) take 7/16” x 48” dowels and cut 42 pcs to 2 ½” in length.
To cut the dowel pins holding the shelves to the legs take 7/16” dowels and cut 12 pcs to 2” in length ( Parts I ) and 4 pcs to 3” in length (Parts J ).
This concludes the cutting and drilling of all parts.
This section is top and lower shelf assembly.
To assemble the top shelf take the lower top shelf side pc ( Part B ) and place on hard surface with holes up.
Insert 7/16” x 2 ½” dowels ( Parts H ) in each hole. Sand a slight taper on both ends of all dowels to make an easier fit.
Then take an upper top shelf side pc ( Parts A ) and place on hard surface with 7/16” holes facing up.
Take the lower top shelf side pc ( Parts B ) with the short dowels in place and turn over and guide dowels into holes in upper side pc. Tap in place until finished height is 3 ½”
Repeat this step for other side.
To assemble the end cross pcs to the top shelf take the top shelf lower cross pc ( Parts D ) and place on a hard surface with the 6 holes facing up. Insert 7/16” x 2 ½” dowels into holes. Take top shelf upper cross pc ( Parts C ) and place on hard surface with holes up.
Take top shelf lower cross pc and turn over and guide dowels into holes in upper cross pc. Tap in place until finished height is 3 ½”.
Repeat this step for other end.
Take one top shelf upper and lower side pc assembly ( Parts A,B,H ) and place on hard surface with holes up. Insert ½” x 19 ½” Dowels ( Parts G ) into holes in assembly. Take other side assembly and place on hard surface and guide dowels into the holes.
Tap down until depth is 20” overall.
Take one end assembly pc ( Parts C,D,H ) and place on end of ABH assembly as shown. Take a 7/16 x 2” dowel ( Parts I ) and drive into hole at each corner as shown. Apply glue to inside of hole.
Repeat step for other end pc.
The top shelf assembly is complete.
To assemble the lower shelf take one lower shelf side pc ( Parts E ) and place on hard surface with holes facing up.
Insert ½” x 19 ½” dowels ( Parts G ) into holes.
Take other lower shelf side pc and place on hard surface with holes facing up. Turn Part E with the dowels inserted over and guide dowels into holes in other side pc.
Shelf depth should be 20” when completed.
This concludes the top and lower shelf assembly.
This section is for the assembly of the top and lower shelves to the 4 legs
To assemble legs ( Part F ) to top shelf assembly turn top shelf assembly upside down and insert legs at each corner as shown. Line up holes and tap a 7/16” x 3” Dowel ( Parts J ) through hole of top shelf lower cross pc ( Parts D )and into leg. Apply glue to inside of hole.
Repeat for all four legs.
Turn top shelf assembly upright standing on legs and tap a 7/16” x 2” Dowel through top of upper top shelf side pc and into hole in top end of leg.
Repeat for all four legs.
To assemble lower shelf assembly ( Parts E, G ) turn table on end as shown.
Position lower shelf between the four legs at the lower holes.
From the top, tap a 7/16” x 2 Dowel ( Part I ) into both legs and then turn on other end and repeat for remaining two legs.
Turn table in upright position and apply wood buttons to all required holes. Apply glue around the edge of hole first.
Lay the Plexiglas on top of table and your project is completed. You can also stain, paint or polyurethane.
This video is posted on our website at madisonmill.com along with our customer service info if you need further assistance.