This project is by Range Woodworking. This DIY side table tutorial shows how to create a stylish and practical piece of furniture using simple box joints and affordable materials.
Step 1: Selecting and Milling the Wood
The first step is selecting and milling the wood for the project. Tasmanian Oak is used here. The boards are cut down to manageable pieces using a crosscut sled on the table saw.
Step 2: Creating Straight Edges
Without a jointer, straight edges are created by identifying the straightest side and marking it to run against the fence on the table saw. A glue line rip blade is used to get clean, straight cuts.
Step 3: Gluing Up Panels
The panels for the top, bottom and sides are glued up using supports to keep everything aligned. Cauls help keep the boards flat during glue-up. Baking paper prevents glue from staining the clamps.
Step 4: Sanding the Panels
After the glue dries, the panels are sanded smooth, starting with 80 grit and progressing to 120 grit. Sanding is done both across and with the grain to avoid scratches showing through in the final finish.
Step 5: Cutting Box Joints
A custom box joint jig is used with a router to cut the box joints. The jig allows for repeatable, precise cuts. The router bit height is set just slightly thicker than the material.
Step 6: Dry Fitting and Adjustments
After cutting all the joints, a dry fit is done to check the fit. Any necessary adjustments are made, like trimming the end groove to match the others.
Step 7: Gluing Up the Box
Gluing up box joints can be tricky. To keep things square, spacers cut to the inside length are used. The water-based glue causes the joints to swell, so clamps and a rubber mallet are used to close everything up tightly.
Step 8: Filling Gaps and Sanding
After the glue dries, any gaps are filled with a mixture of glue and sawdust. The joints are then sanded flush.
Step 9: Rounding Edges
A small roundover is applied to all the edges using a router. A chisel is used to continue the roundover into corners the router can’t reach.
Step 10: Applying Finish
The table is finished with Rubio Monocoat oil in “Pure”. This finish is durable, enhances the wood’s character, and is easy to apply. It’s massaged in with a Scotch Brite pad, excess is wiped off, and it’s left to dry for 24 hours.
The result is a stylish, minimalist side table perfect for any couch. This project demonstrates how simple joinery techniques can create beautiful, functional furniture with just a few tools and some affordable materials.