Folding Leg Work Table

hello today I'm going to be making a wooden work table with folding legs the materials for this project are 4 2 by 3 s 1 1 by 4 some assorted fasteners and for the top I've got a quarter sheet two foot by four foot or five eighths plywood that I'm going to top off with some quarter inch MDF first I need to mark and cut the two by threes for the frame of the table I need two sides that are 45 inches long and two ends that are 18 inches long I also need to cut four legs the length of the leg is determined by how high I want the table to be less the thickness at the top which is going to be 7/8 of an inch some of these two by threes are a little shaggy feeling on one side so I'm going to go ahead and give those a bit of a sand there that's better I need to mark some screw hole locations on both ends of these 45 inch long sides I'm going to put the screws three quarters of an inch in from the end and half an inch in from each side so I'll just use these handy marking blocks of mine I also need to drill a quarter inch bolt hole at each end of this as well now I'm going to want that hole to be two and three quarters of an inch in from the end and centered since I'm going to have to drill quite a few bolt holes I took and I measured the center of this piece of scrap two by three and mark the line now I can use that as a marking guide I also need to mark one end of each leg for a quarter inch bolt hole I'm going to want that inch and a quarter in from the end and centered and on the legs I need to make that mark on both sides I wanted that marked on both sides because I'm going to round over the end of each leg I'm going to set my compass to inch and a quarter and Mark a line on each side so now I'm going to drill my quarter inch holes I've got this extension attached to the drill press and I got a couple of blocks on it so I don't drill into this extension now it's very important that once I get this lined up that I make sure I push firmly down that way I'm going to get a nice straight hole you can use a hand drill but it's pretty tough to get a straight hole if you try to drill all the way through like this unless you're very talented usually end up with a hole that's pretty crooked a better way to do it is to carefully mark both sides then you drill about halfway in from each side and you should end up with a fairly straight hole it's also very important to make sure that your drill bit doesn't stayed out of position when you start drilling the holes you end up with a much better result next I want to round over the end of the legs that I marked with the compass and to do that I'm going to use my belt sander but first I want to clean my sanding belt a little bit so I got one of these cleaning sticks it's made out of kind of a rubbery plastic they work really good just have to be careful that you don't Jam the belt it's time to assemble the frame these 18 inch long end pieces go on the inside like this I'm going to secure these with some self drilling self countersinking screws now you don't have to use self drilling self Congress thinking screws important thing is just make sure the heads are countersunk now even though these are self drilling I'm still going to drill some holes that way I can make sure nothing splits on me once the frame is screwed together I can attach the legs using quarter inch by three and a half inch long hex head bolts I'm also going to use fender washers and hex nuts now on this end the legs go on the outside it doesn't need to be real tight for now at the other end the legs go on the inside it's important to note that fender washers also go on all the bolts on the side where the nut goes next I want to put a cross brace across each set of legs down here towards the bottom somewhere but first you may note how it's kind of sprained out of it in a few places so I'm going to clamp this all up so it's nice and straight the brace for these inside legs are going to be about 18 inches less than 16 for the outside legs it's going to be 24 inches less than 16 I'm going to cut those from the 1 by 4 I'm going to mark some screw locations 3/4 and 3/4 should be pretty good I also want to make a mark on the other side of the board right in the middle I'm going to use this 2×3 as a spacer I'll just line it up so it's even with the bottom of the legs I'll clamp it down pre-drill it and then attach it with these screws then I can do the same thing with the short brace on the inside legs with the cross braces on I can unfold the outside legs and then the inside legs the next thing I need to do is to use some 2 by 3 to put a stop across each set of legs like this now after cutting the sides and the ends and the legs I've got this one piece left over and it's too short to make both stops so that's why we needed to have four two by threes but at least two by threes are cheap and it doesn't hurt to have some extra on hand in case you mess up the bullet holes in one of the legs or something I put a clap at each end now as long as it's nice and tight here and this is nice and tight up against this the legs should be perpendicular remember that spot that I marked here in the middle of these cross braces that's where I'm going to attach a small angle bracket but before I put that on there I need to drill out one of these holes so that a quarter-inch bolt can pass through it I want to make sure that the screw goes into the hole that I didn't drill for the bolt those brackets are going to be the attachment point for a long piece of 1 by 4 that's going to act like a brace to keep the legs from folding up but measures don't to be 41 and a half inches well I'm going to add another eighth of an inch to that so that way that legs will be nice and tight I actually cut this a little bit longer than I said because if I put it in it's too tight I can always make it shorter but I can't make it longer now I want to mark a line at each end about one-inch long down the center that's going to help me ended up on the brackets I can put the brace up on the brackets and then line up that line so it's in the center of that top hole of the bracket I'm going to mark where that hole is with a nice sharp pencil I'm going to put a 1 inch long quarter inch bolt and each of these brackets and secure it with a hex nut so now I need to drill some holes into this long brace to fit those bolts I also have to make a larger 5/8 hole to make room for the nuts that are holding the bolts onto the bracket best thing for that is either a Forstner bit or you can use a spade bit just doesn't make this nice a hole now it's very important that I don't drill that all the way through I only want to drill it about the thickness of the nut once I've got those 5/8 holes drilled I'm going to drill a hole for the bolt that's a quarter inch bolt but I'm going to use a 9/32 drill bit to make sure that this can slide on and off easily so you pop the brace on like that and secure it with a coupling nuts and that'll keep the legs from folding up when you're using the table as for these brackets now that I've tried this a couple of times they do kind of want to swivel around a bit so I probably should have used a bracket like this that has two sets of holes oh well live and learn much to my disappointment I discovered that I didn't quite round this leg over enough stick it up a little bit high well it's no big deal I'm sure it would still work pretty good but I'm fussy and it's not that big of a deal for me to fix this right now I just need to take the brace off then I take the link bolts bottle then I just pull this whole leg assembly out and I can take it over and sand it down a little more this is the 5/8 piece of plywood I've marked some screw hole locations on it the screw holes need to be two and a quarter inches in from the side that way they're going to line up into the center of that frame it's also important when figuring out where the screws go to take into account these screws that are holding the frame together you want to make sure that you don't have a screw coming in and hitting those so just keep that in mind when your plot note where to put your screw holes i've merked all my screw holes I'm going to turn this over now the frame is sized so that it is an inch and a half smaller all the way around than this sheet of plywood that's the same thickness as a two by three so I'm just going to take one piece and clamp it onto the end of this board like that and I've got this little bit longer piece I'm going to clamp onto one side now I can take a little block like this and see how even it is a little bit of fine-tuning and then I'll take some of my larger clamps and try to get them in so they're actually clapped underneath the table frame then I'm going to screw this 5/8 top down with some countersinking screws it's important to make sure that these screws are nicely countersunk once I got this screwed on I'm going to take it and flip it back up on my table from it now I'm just going to double check to make sure that the legs work smoothly so now that I'm sure the legs work smoothly I'm going to go ahead and tighten the bolts up a bit tighten that right up and once each one is tight it's best to put a second nut on it then using two wrenches you hold the one nut solid and tighten the second nut up against it this acts as a lock nut but even with that after the legs have been open and closed a few times they might loosen up so you might have to tighten those periodically now it's time for me to attach this piece of quarter inch MDF it turned out that this quarter sheet of MDF was a little bit bigger than this quarter sheet of plywood so I had to cut that to size I've marked some screw hole locations around the outside of this MDF what 3/4 of an inch in as well as a few of the metal now I don't have any self countersinking screws that are short enough to attach this anything I have will be so long that it pokes through the bottom so I'm going to have to go ahead and countersink these manuals so there's the finish table it's got a nice smooth talk and this inch and a half overhanging provides a convenient place to put a clip to fold there unfold the legs it works best if you tip the table up and then lean it up against something this brief store is in there like that I mean that's back on the bullets and then you just fold the legs and making sure you fold these inside legs in first it's got a little bit of weight to it but it's not too bad when you're ready to use the table hold down the outside legs and the inside legs pop this brace on and you're ready to go should come in pretty handy thanks for watching

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