Building an Outdoor Table (Part 3)

In this post, we are going to wrap up this project; I'll talk about the joinery I used, and why and then get into the finish for this outdoor table, and why. To recap, in Part 1 of this series, I went through the table design and the wood I selected for this project, which is white oak. In Part 2 I focused on milling the wood and prepping the individual pieces for the joinery. I also covered the layout of the pieces to try and orient them the best way possible to give the greatest visual appeal. In this post, we are put it all together and get it to its final resting place.

Joinery - Drawboring

As with any table, the obvious choice for the apron to leg joint is a mortise and tenon joint. It is a strong joint and has been used for centuries because of its durability and strength. So, when I was planning this table design, I knew I was going to use a mortise and tenon joint, but I also decided to take it one step further and add a drawbore to the joint. I covered what a drawbore joint is, and how to make one in this post so I suggest you hop over and take a look to get more of the details.

In order to make this joint, I had to use my drill press to drill out the bulk of the material; these legs were too tall for my mortising machine, which was a disappointment and I may have to address later on down the road. As you can see in the photo below, once the mortises were rough drilled out, I had to finish the joint by hand with a mallet and chisel. 

One thing I should mention is, I had already cut the tenons and used the tenons to layout the mortises. You can see the layout lines in the above photo. Once the mortise and tenon joints were done, I dry fit everything everything to get a feel for what the table would look like.

It was at this point in the process that I also noted that the table looked too boxy and needed some help. What I decided to do was to put a very slight taper on the two inside faces of the legs, meaning, the side where the table rails are. However, I wouldn't cut those tapers until I have the drawbores done. Below you can see the table base completely assembled and you can also see the slight taper I put on the legs; nothing too much, but just enough to give it a little something.

Once this glue dries, I just need to trim the dowels from the drawbore pegs and finish sand.

Outdoor Finish

You can go back to Part 1 of this build and read why I chose white oak for this project, but since this table is going to be outdoors, year around, I wanted to select a highly durable finish. So, I did some research on this and there are a number of finishes that you can use for outdoors, of course there are. But many of them require near constant attention and refinishing annually; I didn't want that. So, I drew upon my boating hobby, as I did in selecting white oak (boats used to be, and are still, made from white oak) and I decided to go with Epifanes clear varnish finish. Epifanes is used in the boating industry to be a sealer for wood on boats, to protect it from the water and sun, which is exactly what  I wanted with this table. 

The application of Epifanes is kind of a hurry up and wait process. You thin the product out 50/50, apply, then let dry for about 24 hours. Then you thin less and less as you build up the coats. In all, this table has 5 coats of Epifanes on it. This Epifanes finish should last a few years before needing to be recoated. The nice thing about it is, you just need to give the piece a light sanding, then apply a couple more coats and then you should be good for a few more years. So, here is the finished table in its final resting place and ready for years of use.

That is all for now. I have a few other things in the works, and possibly a big announcement in the not too distant future so stay tuned!

Outdoor Table (Part 2)

In the first part of the outdoor table build, I started with the design, wood selection and then I began to mill the pieces for the legs. In this second part of the build, I am going to focus on milling the rest of the boards for the project. That means the top, the aprons and finishing the legs. From there, it will be off to shaping the legs and doing the joinery, then the finish.

The Top - Layout

This is my first time working with white oak, and so far, I like it. I'm not a big fan of oak in general, but that is just because I prefer other woods, such as walnut, cherry and mahogany. When working with the pieces for this top, the wood, in its rough sawn form, I find it a bit of a challenge to imagine what the pieces will look like after they are milled. This is a shot of the pieces prior to milling:

To me, it is not easy to see what is under there, but we'll mill it and see what we see. After the pieces are milled, I will work with all of the pieces to see what is the best layout for the top; which is most appealing. Here are the pieces after the initial milling:

I think I got some good grain matching, but I also tried to get the pieces paired according to their width. Here is what I came up with for the top layout; then off to the clamps.

I'm happy with the way this came out. Some of the pieces were pretty gnarly on the edges and so milling was a bit tricky. I tried to limit the amount of white, sap wood, and get nice grain. At this stage, I let the pieces sit overnight, then put them over the jointer and through the planer to their final thickness. Then, off to the clamps for the glue up. While that was drying, I milled all the rest of the pieces. Here is the final stack of all the pieces required for the table; note the giant laminated legs.

In the next post, I will cover the joinery used for the legs and aprons (hint: you can find that here). I will also dry fit everything and get it ready for final sanding and the finish. So, in part 3, we will wrap this beast up and get it done!

Building an Outdoor Table

A friend of mine recently bought a house here in town and the house has some really great outdoor space in the back. He has a nice deck, that leads down to a nice patio where there is a hot tub and a pool. The house has a large built-in gas grill, but he is more of a Green Egg guy, so he bought a really big cedar table that the Egg sits in and then has a large granite top; huge space. The one thing that was missing was a large table to entertain people outside after all that cooking on the two grills. So, he asked if I could build him a large dining table for the deck and I said "of course!".

Design

He wanted a table that would be able to comfortably seat 6 people, with unobstructed leg room. He also wanted it to have look hefty; a.k.a, manly. We kicked around the idea of a trestle style table, but he wasn't keen on the idea of people potentially hitting their legs on the cross members. So, we decided on just a traditional 4 leg table, but with the legs pushed to the edges of the table for maximum room. The legs are going to be 5" square, BIG! I also had in my mind that we would put a little taper in them, but I wanted to wait until the legs were milled up before bringing up the idea.

The table was going to have smaller than normal aprons connecting the legs to allow for someone to pull real close to the table if need be. Lastly, the top was going to an inch thick with the boards running the length of the table, not laterally as is often done on long tables. For the top, I had recommended breadboard ends, which he ultimately did not want, but I think he may ultimate regret that (more on this later on). The reason I pushed for the breadboard ends is that it helps to keep the top flat by not allowing it to bow and cup, but still allows for the wood to move with natural, seasonal expansion and contraction. 

Wood Selection

Because this table was going to be used outside, I needed to select something that was going to withstand the punishment. Here in the South, we don't have extreme seasonal swings, but we do get a taste of all four season, but Summer is the most brutal with the heat and humidity. At first we were going to use White Cedar, but I could not source pieces thick enough for our use. My second wood of choice, which is what we ended up selecting, was White Oak. I had done a lot of research on the use of White Oak for outdoors and it had great results. I also figured, if they can build ships out of it, that last hundreds of years, why not a table?

So, off to my favorite wood store, Peach State Lumber here in North Atlanta. This is my go-to store because they have just about any kind of wood you want, in just about any size you want. So, I had done all the calculations of the amount of wood I thought we would need, and loaded up. 

As usual, I always get rough sawn wood and then mill it myself. I have the equipment and it saves money.

Bottoms up!

In building the table, I wanted to start with the legs first, for a couple of reasons. First, the legs were going to set the tone for the overall table. Second, to get the desired leg thickness, I was going to have to laminate 3 pieces together so this was going to require extra milling and glue time, which meant it was going to be the most time consuming part of the project. Once we joined and planed the pieces nice, smooth and clean, we glued them up.

Once the the glue was good and dry, I used a card scraper to get the bulk of the glue nibs off, and then I used a No. 4 to clean up the rest. 

Once I had the glue cleaned off, I ran the pieces over the jointer again, to ensure they were square, and then finished them in the thickness planer to mill them to their final dimensions. The result is some very big table legs! 5"x5" White Oak. Each leg probably weighs in the neighborhood of 40lbs.

Next Steps

The next part of the project will be to begin milling the boards for the top and the aprons. Once the aprons are milled, then it will be time to do the mortise and tenon joinery. So, come back for Part 2 of the outdoor table build and see how we handled that process. Thank you and be safe!

Office Desk Build (Part 1)

Now that my new shop is in mostly working order, it is time to build something! The first "major" build is going to be an office desk for our house. The design called for something "a little different" which really just meant, not the usual straight legs. Because the area where the desk is going is not really large, and also not a primary working space, it does not need to be very big nor complicated. Of course, I've been given "artistic license" to make some modifications as I see fit, provided the are not too drastic; whatever that means. Basically, this desk will have legs that are slanted on an angle in the front and the back; 3.5 degrees to the back and 7 degrees to the front.

The Lumber - Milling

The desk will be made from all cherry, which I procured from my favorite store, Peach State Lumber. It calls for 4 legs, 4 aprons (2 side, front and back) and a top. There won't be any drawers so that this does not become a catch-all for random "junk". I usually get started with a chalk layout of my pieces, as I picked them in the store.

Because I am not using plans, and sort of making this up as I go, I thought I would start with the legs. I kind of came up with the 3.5 and 7 degree dimensions by using a piece of 1x4 pine material and a compass square to find an appealing angle. In the picture above, you can see that I marked a triangle for the legs so that I can try and keep them oriented as best as possible as I go through the process. Once I rough cut them, I will mark them with pencil on their ends in the same manner. Here they are milled to near final dimensions, which is 1.25" wide by 2.5" deep (thick) by just over 30" long.

Measuring and Layout

Once the legs were milled to dimension, I needed to determine an appealing length and layout for the two side aprons. Here, I simply have the milled apron piece clamped to the legs so I can come up with an appropriate length.

This length needs to take into consideration how deep the top of the desk will be and the front and back overhang of the top. Too big and there won't be a lot of room, too small and it could make it unstable. Once I determine the apron length, I can make a pencil mark to define the shoulder of the tenon that will be cut into the apron; I will be doing double mortise and tenon joints on these legs because the aprons are 5" wide and one long tenon would, in theory, not be as strong as splitting it up. 

Next Steps - Lessons Learned

The next step will be to cut the tenons into the two aprons. I will be cutting these by hand as I think it will be easier than trying to mess with multiple machine setups and potential mistakes. Once the tenons are cut, I will use those to mark for the mortises, which will be cut on a mortising machine; I "cheated" a little on how I did this so you'll have to see what I did.

I also wanted to close with a little lessons learned; I think it is important to impart things I figure out along the way, for those that may not have done this before. None of this is the "right way" per se, just how I did it. First, make sure you have a good compass square that can really lock in place. Second, as far as possible, make all layouts for that particular angle at the same time. For example, I measured all my 7 degree angles before moving on to my 3.5 degree measurements. If you don't do this, take the time to mark and cut a scrap piece that has these measurements on it so you can quickly get your measurements from it later if you need to. Lastly, similar to the measurements, make all angled cuts for the same setting at the same time. This keeps you from having to move your miter gauge back and forth and having errors, or worse, losing track of which cut is supposed to go where and making a mistake. 

So, next time it will be mortise and tenon cutting time and, hopefully, a dry fit of the two sides.