This is a quick and dirty explanation of how the tables were put together.

First cut the bottom oval (3/4" MDF or Oak/Birch plywood) and the railing (1/2" MDF or Oak/Birch plywood) oval out so they are exactly the same size. Then cut out the railing oval 4" in so you have a big 4" ring for the railing.

Next step cut a 1.5" ring off of the bottom oval and glue/screw this to the railing oval with countersunk screws. This way you have a rim attached to the rail that fits perfectly over the bottom oval, no matter how bad your jigsaw skills ;) Then belt sand the rail (inside and outside edges) to smooth everything over, then router off the three outside edges of the rail (inside/outside on top and outside on bottom ... where the foam/vinyl will wrap over) with a roundover bit.

Next glue the foam (3M spray adhesive) and staple the felt (electric stapler a must, and 1/2" staples) to the bottom oval. Pull the felt tight and put a few staples on all four edges, then go half way in between, etc. pulling tight until completely lined with staples. Then put the bottom/rail together and drill holes through them with a small pilot drill, then use an arbor bit on top bottom to create counter sinks. The pilot hole keeps the counter sinks aligned. Then widen the pilot holes with a drill bit big enough for the bolts.

Next put tee-nuts into the railing top. This way you can bolt the rail on from the bottom. Then apply the foam/vinyl to the rail (5/16" staples), place rail over bottom and bolt them together. Be sure to trim away vinyl so it does not cover the bolt holes! Then attach the underlayment (1/8" masonite), scotchguard the felt, and thats pretty much it!

Send questions to monte at ohrt dot com

back to picture gallery