Before my friend Ken left on an extended vacation, he stopped by at the shop and dropped of 16 solid Black Walnut blocks to be integrated into a unique end table design. We discussed the details, and I started the process of CAD drawfting the table bases. This week, Ken approved the drawings, and I was able to order materials and start fabricating components for these tables. Here are some pictures!
Here are the 4″ by 4″ solid Black Walnut blocks after Ken dropped them of at my shop.
These blocks are to be held in place and properly spaced by a grid. Here are the first pieces of the grid after plasma cutting.
After cleaning the pieces I slid them into each other, aligned and squared them on my welding table, and tack welded them together.
Here is the first test, and the blocks fit nicely in there. Now I felt comfortable to cut the remaining pieces for the other two table base grids.
Here are all three welded together, after finish grinding.
Today I cut the frame parts on my dry cut saw, and prepped them for welding. Ready to go!
All flat frames welded!
Finish grinding all the welds!
Welding the center frames together with one of my weldings squares as a jig.
This is what the finished top frame looks like after all three frames are welded together.
Getting the first grid ready to be inserted into the top frame.
After grinding a minimal amount of the ends, I was able to pound the grid into the frame with a rubber mallet. The spacers in this picture help me to get the grid to the correct height inside the frame.
I set up the frame on some spacers to test all the blocks!
Here are the outside blocks all in place.
Right now it is upside down, but helpful to check it all out!
I added the taller center blocks into the grid, and it all fits really well.
Another view from a little further back.
And another one! That’s all for today! To be continued on Monday! 🙂