When some people think about woodworking, they imagine using hand tools to recreate classic designs
When I think about woodworking, I imagine using CAD, CNC and power tools to create original designs
The Solidworks model before construction started
Gluing up the leg parts
Jigs for cutting the leg parts
Cutting the leg parts
Cutting the leg parts
Cutting the leg parts
Precision crosscut jig
Labelled to ensure grain consistency
Glued in the dual purpose glue/router jig
Ready for CNC cutting
CNC cutting the outside shape
CNC cutting the exposed "dumbell" reinforcing joint
2 inch deep cut with 1/4" bit, 0.060" per pass
Test pieces for selecting contrasting wood
Cutting a test piece
Drill jig for cutting nut pockets
Nuts fit in the pockets
Nuts welded to 0.1" steel plate
Recess cut in wood cap parts
Steel plates screwed into legs
Steel plates before being screwed into legs
Caps glued into place and clamped with bolts
Cutting the crossmember
Sanding the frame pieces to thickness with 36 grit drum
The table top was made using 1/4" plywood skins over a glued-up frame
This provides great stiffness with reduced weight
Holes in bottom reduce weight a bit more
They also make a cool pattern
And provide convenient hand holds
Router table was not big enough to cut all the holes in one setup
Moving the table top around the shop
Test fitting the legs..everything lines up correctly
Resawing the top veneer
The top veneers after drum sanding
Vacuum bag setup for gluing the veneer. Plastic resin glue was used to reduce creep
Vacuum was applied for 6 hours
CNC cutting the outside contour
Each pass was 0.06" to avoid chatter with the 2" long bit
The thin triangular sections made some strange sounds right before they separated
One side finished
CNC cutting the inlay pockets
After flipping and aligning, mill the other side
Outside contours line up perfectly
All inlay pockets done
CNC cutting the inlays
The back of the veneer was covered with plastic tape
The veneer was cut on a vacuum table that held it in place
Paper covered the unused vacuum holes
The finished inlays ready for glue
The inlays were also glued with plastic resin and vacuum clamped
CNC cutting the edge trim pieces
The edge trim pieces serve to alternate the joints on the edges
They fit into a routed groove on the table top edge
The large radius edge pieces are 0.5" thick, and are bent around the edge
This provides a tongue and groove glue joint
A CNC cut caul protects the edges while clamping
..and clamping
..and more clamping
Long pipe clamps used for the short sides
Lots of clamps
..clamps
CNC cutting the corner parts
The Wenge was too stiff to bend even when cut thin
A jig was used to finish cut the ends of the edge pieces
Ball bearing bits, light 0.06" cuts taken to reduce chatter
Clamping the corner pieces
..and clamping
...and more clamping
...and more clamping
After rough sanding
After edge routing and finish sanding
Ready for finish
Testing epoxy finish on small piece
Epoxy does not go on smooth
..or free of bubbles
Light coat on bottom
Steel attachment bracket mounted to top of leg
3/8 - 16 threaded insert
Installed into bottom
LOTS of sanding with the straight-line sander. 80, 180 and 320 grit
Final wet sanding with the random-orbit to 600 grit
A mirror shine was not desired
The legs were shot with semi-gloss conversion varnish
The top was waxed with automotive wax
This resulted in a nice satin shine
End view
The finished product