DIY Network

Freeform Furniture: Putting the Patio Furniture Together From "Freeform Furniture" episode DFFF-103

In this third segment host Amy Devers puts the cylinders together for the patio furniture and attaches the feet.

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Host Amy Devers attaches the top, the bottom and the legs to the patio furniture.

Materials:

Prefabricated plywood cylinders
1" x 1" glass tiles
Plywood
Solid surface material
Prefabricated furniture feet
Combination square
Pencil
Screws
Wood glue
Clamps
Glue
Small drill bit
Safety glasses
Thin-set white mortar
Trowel
Wooden board
Spray bottle
Bucket
Dollop
Tape measure
Double stick carpet tape
Dust mask or respirator
Chamfer bit
Sanding block
320-grit sandpaper
T-Nuts
Polyurethane construction adhesive
Caulking gun
Framing square
Bright white sanded grout
Hard rubber grout float
Big sponge
Water
Cloth
Dental tools
Grout sealer

Tools:

Jigsaw
Table saw
Drill
Band saw
Router
Rubber mallet
Circle cutting router jig
Flush cutting bit
Drill press
Hammer
Forstner bit

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

Putting the Patio Furniture Together

Note: The core cylinder has been constructed and covered with tile. Normally you would apply grout now, but you need to wait until the top and bottom are in place and then grout everything at one time.

Solid surface is perfect for outdoors because it is weatherproof, non-porous, and heat resistant. It comes in a wide variety of colors and while it looks like stone, it works like wood (figure A). You can use common wood working tools to cut it, rout it, and even sand it. You can't purchase this at a home center store, but you can order it from a solid surface distributor.

1. To cut circles out of the solid surface you need to measure the diameter of the cylinder which has changed now because of the added mortar bed and tiles.

2. Once you have the correct diameter, use a circle cutting router jig to create a plywood template for the same diameter.

3. Drill in the center of the piece of plywood and fit the pivot point on the arm of the jig into the drilled hole. The pivot will guide the cutting bit of the router in a perfect circle. Apply downward pressure while guiding the router in a clockwise direction while cutting the circle template (figure B).

4. After the template is cut, lay it on the solid surface material and adhere the solid surface.

5. Cut circles out of the solid surface using a band saw (figure C) -- and again cut a little proud of the line.

   Note: A jigsaw with a special blade for solid surfaces can also be used.

6. Attach double stick carpet tape to the circle template and adhere to the solid surface. Clamp it down for extra stability.

7. Use a router with a flush trimming bit to trim the solid surface material flush with the template (figure D).

   Note: Cutting solid surface material creates a lot of dust, so a dust mask or respirator is required.

8. To make a decorative edge, go over it again with a router using a chamfer bit at a 45-degree angle. The bit has an angle to it so it puts a bevel on the material (figure E).

9. Use a sanding block with a 320-grit sandpaper to finish the edge.

10. Before you attach the top and bottom pieces to the cylinder, you need to prep the bottom for the legs. Each leg is topped by a threaded rod that screws into a special fastener called a T-Nut which is sunk into the plywood. It is tricky getting the hole in the solid surface to line up with the T-Nut in the plywood. Drill the holes in the solid surface first and then use that as a template.

11. Mark the positions of the three legs on the solid surface bottom. Use the drill press to make holes for the threaded rods on the ends of the legs. Use the solid surface as a template to mark the plywood beneath. Use an awl through the holes in the solid surface and then tap it with a hammer to mark the plywood.

    Note: The T-Nut gets that name because it is shaped like a "T". If you want to install a T-Nut, you need to create a T-shaped hole so that the head of the nut fits in there flush. To do that you need to use a special drill called a forstner bit. The forstner bit cuts the wide, shallow part of the hole to accommodate the head of the T-Nut.

12. Drill each of the marks with a forstner bit. Drill all the way through the plywood and just deep enough for the head of the T-Nut (figure F). Using a regular drill bit, make the holes to receive the shaft of the T-Nut. Hammer the T-Nuts in place.

13. After the T-Nuts are in, attach the solid surface bottom and top using a polyurethane construction adhesive. Use a caulk gun to apply a nice thick bead onto the plywood bottom.

14. Position the solid surface material and center it on the structure making sure to line up the holes with the T-Nuts.

15. Thread the legs through the solid surface into the T-Nuts helping to hold the bottom in place (figure G). Let this set for ten minutes and then flip it over and repeat the process on the top.

16. Use a framing square to ensure that the top and bottom are flush to the cylinder.

17. Put a few clamps on the table to hold everything in place. Let the adhesive cure for 24 hours.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Glass Tiles
Website: www.crossvilleinc.com

Solid Surface Materials
Pinnacle Distribution Concepts
Website: www.pdc4surfaces.com

Woodcraft
Website: www.woodcraft.com