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Published at Wednesday, November 07th 2018. by in Kitchen Table.

I'm going to be building a base for a new kitchen table. If you want to see what I did stick around, let's make it now. I picked up some redwood at a local lumberyard for a great price. I cut this 4x4 into a couple equal sections. I would be using a lap joint, so I marked out the sections I would need to notch out. I also scribes a line to remove the middle sections for a decorative look, and I marked where I would round the ends as well. My table saw blade, can't cut the entire 4x4 in one pass. I lower the blade just above halfway to make two passes to make the necessary plunge cuts.

I remove the riving knife and replace the insert. I lined up the cut and very carefully plunge down on one side, slowly cutting and then pulling out. I made the cross cuts using the table, saw sled by slowly approaching the line and then use a handsaw to finish. The rounded uncut sections left by the table saw blade using a hand, plane and a chisel. I cleaned up the bases and then sanded them smooth. I still don't own a handsaw, so I had to use the jigsaw to make these small rounded cuts. It went horribly, but I was able to clean them up on the drill press with a drum sander. I rough cut the outside corners and made them smooth on the belt sander.

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Small Round Kitchen Table And Chairs
Small Round Kitchen Table And Chairs

With a little sanding. They turned out pretty good to make the lap joints. I replace the normal table saw blade with my dado stack. I make several passes with the stack and creep up on the line. I don't want to go past it once I'm at the correct depth. I can now notch out the rest of the wood between the lines. I leave the lines for now and can fine-tune them later for a perfect fit. I repeat the same process with the other foot.

Now you can see the two pieces come together as one using an inch and a half force. I hog out the majority of the material right in the center of the lap joints on each foot. I drill down most of the way but finish the cut from the other side to minimize blowout. I use a razor knife to establish the mortise line. This will also lessen the risk of chip out farther than I want with a small chisel. I can carefully remove the top section and then pound out the rest.

These are how the two mortises line up together - I cut another piece of 4x4 for the main post and mark out a tenon that will fit down inside the mortises. I just cut, I mark out the length of the tenon and then just like before creep up on the line. So as not to go past it, the same process can be done with a regular table, saw blade. It would just say quite a few more passes. Now I can trim it down to its final length. I put the post and a bench vise and cut the tenon right in half, starting with a coping saw and then with the larger handsaw.

I also quickly cut a small wedge. I apply a generous amount of glue to the tenon and add the two-foot sections once in place. I hammer the wedge down into the tendon, locking everything in place. I cut two equal lengths of 1 by 4 and then miter the edges to 45 degrees. At the table, so I rip both edges just to clean them up. Just like the first set of lap joints, I use the dado stack to first creep up on the line and then remove material from one line to the other.

It will get a white paint job but sand it back for a warned. Look. I used a few cans of spray paint as it would be much easier to apply them with a brush once the paint was dry. I use some sandpaper to expose the dark walnut color from all the edges. I wet an old shop rag and cleaned up the entire piece. The final step was to apply several coats of spray polyurethane.

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