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19 September 2011

Walnut and Steel Coffee Table

I just finished making this walnut and steel coffee table for a friend. It cost $250 in material and measures 45" square and 18" high. This is my first attempt at building something with high-end materials that's more affordable and light weight. 

I didn't document the production process as well as I usually do, and many of these photos are from my camera phone. It's really hard to stop what you're doing and pick up a camera at every step but as a learning tool it's almost always worth it.

These are some quick sections trying to figure out the edge detail.
This is how the details were actually made using 4/4 walnut and 1 1/4" x 1/8" thick angle iron.
The boards are joined on the short edge with dominos with beech and glue then they're clamped. Those strips on top are the end grain glue-ups/solid strips that make up the underside edge.
Prior to oil.
After the first coat of oil.
Marking the bent corners with a scribe prior to cutting them on the bandsaw. I left thickness on the backside for the opposite flange.
The legs are bent, then welded on the backside of the miter.
This was my first time using a MIG - I learned on a stick / arc welder.
The frame uses 36' of 1 1/4" angle iron (it comes in lengths slightly longer than 20'). The legs and frame are four of the exact same pieces butt welded to one another near the corner. The cross member is needed as the walnut would be too thin to support a substantial load.
More walnut furniture in Crown Hall. Teak oil finish - about 6 coats taken to 320 grit and buffed out with #0000 steel wool. The top is 4/4 (3/4" walnut) with strips of 1 3/8" wide walnut on the underside with grain set perpendicular to the top boards to give the appearance that the table is actually made of boards going opposite directions. Not sure how I feel about that - it's kind of dishonest (in the Dieter Rams sense).
The typical rule for coffee tables is to make them 2/3's the length of the largest couch and the same height as the top of the seat cushion. In this case that makes the table 45" square and 18" high.
Corner detail.
I took some steel wool to the metal frame before rubbing some boiled linseed oil onto it. After about 15 minutes you wipe off the excess. This both protects the steel and makes it darker and leaves a sort of waxy feel to it. This is what farmers used to use to protect their tools from rust.
Here's a short video I made about how I made the one-piece leg-table top supports. It's sped up a bit in the middle of the clip to make it less boring. The 90 degree triangle is removed from the angle iron, then it is bent to 90 degrees, and welded on the backside. I've used the same process to make hundreds of pipe brackets in factories.

3 comments:

Simon said...

Hi,

did you use hot or cold rolled steel profiles?

Simon said...

Hi,

did you use hor or cold rolled steel profiles?

Ethan Smith said...
This comment has been removed by the author.