This project was built and designed by Keaton Beyer. It’s a custom dining table featuring a butterfly leaf that folds neatly into the center, combining elegance with expandability.
Built in response to a client’s request, this table not only meets functional needs but also showcases a clever approach to storage and joinery. With thoughtful design and problem-solving throughout the process, Keaton delivers a piece that is both beautiful and practical.
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Origin of the Design
The idea for this project began in July 2024 when Keaton was approached to build a dining table that could extend without requiring external leaf storage. After considering options, the butterfly leaf concept was selected for its ability to fold in and store neatly inside the tabletop.
The project introduced new challenges, particularly the mechanics of the folding leaf. Even with years of woodworking experience, the technical nature of this build brought a dose of imposter syndrome, which Keaton candidly shares in the video.
Milling and Material Prep
The build began with breaking down rough boards into manageable lengths. These initial cuts helped remove twisted or damaged sections and made the milling process more efficient.
Once the boards were trimmed, they were run through a planer to flatten both faces. Some warped pieces required extra care—hot glue was used to temporarily secure sections during flattening, showing Keaton’s flexibility in adapting to difficult material.
Joinery and Jig Work
With the material milled, the next step was joinery. The legs required compound miters for a clean connection with the aprons, and a custom jig was made to achieve the necessary angles. This allowed for repeatable, precise cuts, ensuring tight-fitting joints.
Floating tenons were used to join the aprons to the legs. This method offered strength without the complexity of traditional mortise and tenon joinery. Keaton carefully marked each piece and performed dry fits to confirm accuracy before final assembly.
Building and Assembling the Base
Once the joinery was complete, the legs were tapered to give the table a more refined look. Tapering not only lightens the visual weight but also adds elegance to the structure.
Despite all the prep, assembly still presented some challenges. Clamping angles and small shifts during glue-up forced Keaton to make minor adjustments on the fly. These moments reminded him—and viewers—that even experienced woodworkers hit unexpected snags.
Designing the Curved Top
The tabletop featured subtle curves along the edges, which required careful layout and routing. Keaton used a template to trace the shape, then refined the cut with a router for a smooth finish.
To level the top and clean up glue lines, hand planes were brought in. This step not only ensured a flat surface but added a handcrafted quality to the final product that’s hard to replicate with machines alone.
Building the Butterfly Leaf
The centerpiece of the project is the butterfly leaf mechanism. This design allows a hidden leaf to fold out from the center of the table, offering expansion without separate storage.
Cutting and hinging the leaf panels required tight tolerances to ensure they folded and fit back together smoothly. Keaton built custom brackets and used a central pipe as the pivot point, allowing the entire mechanism to operate cleanly and securely.
Each component was tested multiple times to ensure smooth movement. The leaf tucks away into the table when not in use, with no extra parts to store—just a simple, integrated solution.
Finishing Touches and Assembly
Once the mechanical aspects were dialed in, final sanding and finish work began. Keaton chose a hard wax oil for its natural feel and protective qualities. This finish enhances the grain and adds durability without making the surface overly glossy.
The table was assembled one final time, with careful checks to ensure alignment across every joint and moving part. The result is a smooth-operating piece that expands effortlessly and maintains its structure under load.
A Meaningful and Challenging Build
This project pushed Keaton’s skills and patience but also proved incredibly rewarding. From layout to final assembly, each step required attention to detail and a willingness to problem-solve.
The butterfly leaf system, while complex, adds a level of functionality that’s rare in handmade dining tables. It transforms the table from a compact setup to a larger seating area in seconds—all while maintaining a seamless appearance.
A Functional Piece with Lasting Appeal
The finished dining table is a standout project that combines clever engineering with classic joinery. It solves real-world problems in an elegant way and provides long-term value through thoughtful construction and durable finishing.
For woodworkers looking to take on something more advanced, this build offers plenty of learning opportunities. It’s also a great example of how pushing through challenges can result in a piece that’s both technically impressive and deeply satisfying to create.
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