With Ron's expert guidance and encouragement, these young women are eager to tackle this project even though most of them have had little or no experience with power tools or construction.
Click Here For a list of what
you will need in order to complete this project.
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1. Begin with a drawing:
- Ron begins by showing the women a drawing of the finished project and explains how the benches will be made using mostly 2 x 6 lumber. They will first bolt together the triangular end frames, then stand them up vertically and add a couple of bench boards and then finish with the top boards. For extra reinforcement they will add braces underneath.
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2. Cut the wood:
- It is easiest to cut all of the pieces of wood for the whole table first, and then begin bolting them all together. Using a power miter box, do all of the straight cuts first and then move to the more complicated angle, or miter cuts. Using the diagram you have drawn, measure and mark the angle that you will cut the lumber. Then use a bevel gauge to transfer that angle to the power miter saw.
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- Because the sorority women were building three tables at once, all with identical pieces, they set up a stop on the saw. This sped up the process and ensured that all of the parts would be exactly the same length.
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3. Assemble the wood:
- With the lumber cut, it is time to assemble the table top and bench supports onto the legs. Once completed, these pieces will make up the end frame. It is helpful to set up a worktable from plywood and sawhorses.
- After setting up the first assembly, it is helpful to mark off the exact location for all the parts onto the plywood. For the remaining pieces, all you have to do is line them up in the marked positions.
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4. Drill holes:
- The first holes that need to be drilled are called clearance holes. These holes are slightly larger than the screw. You will then drive the 2 ½ " rust resistant screws through the clearance hole and into the piece that is being attached. Drilling the holes for the carriage bolts requires a little more muscle. They are larger and must go clear through both pieces of lumber. The carriage bolts will do the real work in holding the end frame together.
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5. Install carriage bolts:
- Putting the smooth bolt head on the inside will keep your legs from getting scratched. Add a washer and nut, and snug it tight with a socket wrench.
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6. Add table top planks:
- Once again, make clearance holes and use the rust resistant screws to attach the planks for the tabletop. Quarter inch spacers will ensure that the planks will be evenly spaced.
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7. Add benches:
- Make sure the outside board overhangs the supports evenly on both ends and the sides. Using a combination square will help keep the offset consistent.
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8. Add bracing:
- To reinforce the construction and give the table more stability, you will need to add bracing to the underside. Add one perpendicular piece of wood to the center underside of the table and attach it with screws. Then add the supports at an angle up against this piece and the leg frames. This will connect the legs to the underside of the tabletop.
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9. Apply sealer:
- A coat or two of sealer will preserve the wood, make the table last longer and keep it looking better as well.
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RESULTS:
In just a few hours, with a lot of enthusiasm but not a lot of experience, Professor Ron was able to graduate his whole picnic table class with straight As!
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