We decided
that a drop leaf would be a great addition to the table top. I know what a rule joint
looks like but haven't made one in 39 years. I did order two bits that will allow me to
make the joint. I ordered a 3/8" radius cove bit (left) and a 3/8" radius
rounding-over bit (right.)
The picture at the right is a sample cut. I started by setting the cove bit
so that it would cut about half way up the side. I then switched bits and adjusted the
rounding over until the piece mated perfectly with the cove cut board. It really worked
very easily.
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Here is a view of the bottom of the sample boards. You will see that I
ordered special "rule joint" hinges. They are offset to allow for the joint.
If you look at the photo above, you will see that I aligned the hinge point
in line with the inside flat of the table section [I have drawn a faint line on the photo
to illustrate this.) In fact, it is 3/8" from the bottom seam.
In the photo at the left, I have simply attached the hinge without mortising
it to see if I was at all close. I was. I will mortise the hinges in the final table top.
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With the sample working
right, I can now cut the actual joint. The table will be made of 3/4" plywood covered
with Formica. I do not want to profile the joint or fasten the hinges in plywood, so I am
using poplar for the joint. I am cutting the table top shape on this pass.
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I install a straight bit that I will use to smooth up the rabbet portion
of this joint.
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This is the table
portion of the joint after the round over and the straight bit doing their work.
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I
have now installed the cove bit and have adjusted the height per my sample. I am running
the final board. The table portion is on the right and the leaf portion is on the left. I
will rip this board in half and join these profiles to the 3/4" plywood portions.
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I want the
poplar/plywood joint to be a strong one, so I have installed the CMT Reverse Glue bit. I
have set it up using a couple of scraps of 3/4" plywood. I adjust the height until my
samples are aligned. Having done this, I can now run the plywood panels.
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Without changing the
bit height, I run the mating poplar pieces.
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This joint is a great one
for having a lot of gluing surface. I use a brush to be sure that I get glue spread
evenly.
I will clamp these pieces and let them set overnight.
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Well, I apologize for
skipping a few steps in between. Sal and I have been working steadily to complete this
table, and I simply forgot to get pictures as we went.
Fact is, you can see what has transpired. We added a base to the pedestal and
attached the plywood top. Then we added a piece of 3/4" MDF to give us a total top
thickness of 1 1/2".
I will show the hardware we used and the adding of the Formica next week.
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