|
Cutting the upper curve on the main leg. This is done in 2 passes, rough cut followed by final cut. There is a separate hole in the table top for each pass (the "rough" hole is 1mm farther from the bit than the "final" hole).
|
 | The 3mm leg blanks
|
 | Upper supports attached
|
 |
|
 | These are sections of 22mm OD metal pipe that I cut from a beach umbrella base, to use as the wire conduit in the legs.
|
 | The leg bulkheads (6 per leg). The wire conduit will need to pass thru these, so they will all need a 22mm hole drilled, and the holes have to line up when they're laid out on the leg.
|
 | I squared them up and taped them together (6 at a time)
|
 | Then I drilled a 1/8" pilot hole thru the whole stack on the drill press. This ensures that the holes are aligned.
Finally I drilled out each bulkhead to 22mm (separately) using a step drill.
|
 | I slid the bulkheads onto the pipe, spaced them out according to the alignment marks, and laid the assembly onto the leg blank.
|
 | Then I glued the bulkeads to the leg blank
|
 | Finally I added reinforcing pieces.
|
 | For the other leg, I used a different technique (got the idea from another builder in the club). I have cut each leg bulkhead into two shorter bulkheads...
|
 | and glued them along the alignments, leaving a space in between.
|
 | Then I added 2 long strips of 2mm cut to the same height as the bulkheads. This leaves a channel for the wires to go thru, and it seems very strong. This took about half the time of the metal-pipe-conduit method.
|
 | Here's the leg ready for the top piece to be added. I've put an M6 screw through the center hole and fixed it with a nut.
|
 | Then I added the top 3mm piece. The M6 screw keeps the parts aligned. I added another nut to keep the whole thing together.
|
 | I flipped the leg over so I could glue the top piece down to all the bulkheads and supports. Most everything contacted the top piece so that they could be glued, but there were a few places where it didn't contact, so I added small 1mm scraps to tie everything together so nothing is left "hanging."
|
 | Two legs ready for skinning. I'm surprised how small the legs are; I guess the ankles will add some length.
|
 | These are the 1mm parts that skin the outer edges
|
 | The long skin that curves around the top. I held this in place with the ratchet strap and some wood scraps, then applied pressure on the sides with some weights.
|
 | The 1mm leg face skins before cutting out.
|
 | 1mm leg face skins. I cut the top curve on the router table
|
 | Adding the face skin
|
 | In order to cut the hole for the hub detail, I inserted a screw thru the center hole from the inside...
|
 | Then put the screw into the hole in the table top. I was then able to start up the router and cut the hole.
|
 | The router leaves a nice clean hole
|
 | Test fitting the resin hub detail. This completes the legs.
|
 |
|