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Dry-fit the tray, including the bottom. The sides will be slightly taller than the ends Fig. A, Detail 2, below. Plane or sand them flush.
Finish-sand all of the parts prior to gluing and clamping. This requires careful clamping, so use glue that sets up slowly. Gluing the bottom in addition to the corner joints makes the tray very rigid.
Just coat the mortises in the ends and run a bead in all the grooves for the bottom. MDF , five in. Our angled clamping blocks were offcuts. Aerosol-spray polyurethane is a perfect finish for this project. Set the tray upside-down and spray the bottom and outer sides first. After the poly is dry, turn the tray over and spray the inside and the top edges.
Spray three coats on each side, sanding between each coat. Note: Product availability and costs are subject to change since original publication date. Seven Corners Hardware , 7corners.
Shape the templates, using Patterns 1 and 2 below. Fasten the fences at the bottom of the templates, exactly parallel. Then fasten the stops so they cradle the blanks dead-center on the template. This story originally appeared in American Woodworker October , issue October , issue Purchase this back issue. Cut dadoes in the mitered ends, using a dado set. A jig made from extra mitered pieces makes dadoing safe, precise and repeatable.
Cut beveled edges on the sides and angled grooves to house the plywood bottom. Use a regular blade to cut the groove, making two or three passes, so the plywood fits snugly. Cut half-lap Best Woodworking Planes Kit tenons on the sides, using the miter gauge, a sacrificial fence and your dado set. Transfer the location of the groove from the side to the end, after assembling the corner joint.
This method is more accurate than using a ruler. Rout both handles from one piece of wood, using a flush-trim pattern bit and a shop-made template-routing sled Fig. B, below. Saw the Free Woodworking Plans Desk Organizer On handles from the blank, using a sacrificial sled—nothing more than a scrap of plywood. Fasten the blank to the sled with double-faced tape, so the small handles stay attached and stable after the cut. Glue the handles on the roughly-shaped ends. Use centerlines and a spacer to hold the handle level and at the right height.
Waxed paper keeps the spacer from accidentally getting glued on. Rout the arched end and the handle at the same time, using a sled and a pattern bit Fig. C, below. Be especially careful not to blow out the protruding front end of the handle. Rout the handle hole. With the power off, center the bit in the hole. Push the sled forward into the bit 1 and advance the cut counterclockwise around the inside of the hole 2.
Make very light passes and go slowly. Angled blocks and a flat surface put clamp pressure on the joints.
First clamp the ends to a piece of MDF 1. Then clamp the sides to the ends, using angled blocks 2. Finally, clamp the ends to the sides 3. Here are some supplies and tools we find essential in our everyday work around the shop. We may receive a commission from sales referred by our links; however, we have carefully selected these products for their usefulness and quality.
By American Woodworker Editors. Serving Tray Make one or many: simple shop-made jigs guarantee success. Miter the ends first Cut the blanks for the sides, ends and handles Fig. Fit the corner joints Set up the saw to cut the half-lap tenons on the sides.
Fit the plywood bottom The last joinery step is to cut grooves in the end pieces for the bottom. Make sleds for routing the curves All of the curved shapes are template-routed, using two shop-made sleds, for safety Figs.
Saw the blanks oversize Install each blank in the sled and mark the curves and cutouts. Learn how to build your own scotch tray using these free step-by-step instructions. Skip to Content. Looking for Something? Search anything and hit enter. Home Trays — All Types. Category Trays — All Types This Do-it-yourself projects category features a collection of DIY free woodworking plans to build many types of trays from woodworking related web sites.
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Actually it ….
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