I’m making a large, 5′ X 10′, eliptical table top for our Fellowship out of “Brazilian teak” flooring (with the tounges & grooves removed). The pieces are, mostly, 1′ to 2′ in length, with a few longer, & 2+” wide. There are about 130 pieces in 22 courses. I’m to the glue up stage; & it feels very daunting, since I’ve never done anything like this before. I plan to cut it into 3 sections after the glue up & then cut the elipse – 1st wilth a jig saw & then with pattern router bit. My current plan is to glue one course at a time, after the first two & work my way across the table. Many of the courses have 6 or 7 pieces in them. I’d appreciate any ideas &/or suggestions (other than to use it for firewood, which I’ve considered. Actually, I’m enjoying the challenge.).
Thanks,
Morty
Replies
I can't help you but I sure would like to see pictures of the progress at different points. Sounds like a real challenge and I could learn something from it.
Brent
Morty:
Since they seem to be several different lengths and widths I would lay out the entire setup on a flat surface, like a floor. It seems like it may be kind of a jigsaw puzzle. Once it's laid out the way you want it, mark all the pieces with lines, and or numbers, in a manner that you'll be able to glue them together, in smaller batches, and end up with the same lay-out. You need to know exactly where each board is going to go before you start the glue-up.
Don't be in too big of a hurry with the glue-up either. Make sure you keep everything flat.
Hang on before you start and get some other opinions.
Good luck,
Jim
Edited 12/5/2009 5:05 pm ET by James R.
To Jim,
Thanks for your input. I do have it laid out on a flat surface & have marked the pieces, so I don't get anymore confused than I already am, as I glue it up. I'm constucting it on a 3/4" plywood substrate, to give it some support. I'll attach it with screws, the parts of which that are in the substrate will have some play, to allow for expansion of the top. The top will weigh about 225#. All the pieces are the same width.
Thanks, again, for your thoughts.
Morty
When I've done stuff like this, I've glued up segments about 11" wide (so it'll fit through the planer) and then joint the segments for the final piece. I would have left the t&g tho' -- helps keep things aligned during clamping when you have butted pieces. How do you feel about biscuits? They would help keep things true during clamping. Either with biscuits or without, I'd clamp them by using a piece of wood running the full length on both sides that's a bit wider in the center than on the ends (a lenghtwise clamping caul) to keep everything tight and straight.
Mike Hennessy
Pittsburgh, PA
Everything fits, until you put glue on it.
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