Operating Procedure Rev: A Wooden Bedside Table Page: 1 of 12

1.0 SCOPE

This describes the materials, tools and instructions needed to build a Bedside Table

2.0 EQUIPMENT

Circular Saw

Power Sander

Router

3/4" Router Bit

Wood Clamps

Tape Measure

Ruler

Calipers

Router scrap wood (flat on one side and at least 2’ long)

Chisel

Hammer

3.0 MATERIALS

Wood Glue

Shelving wood, qty 2, Pine, 3/4” thick, 16”x16” or larger

Leg wood, qty 1, Pine, 3/4" thick, 8”x60” or larger

Optional:

Wood Stain

Polyurethane

Mirror, 11.75”x11.75”

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4.0 PROCEDURE

Note: Wear safety glasses whenever using power tools.

4.1 Measure the shelving wood. Two pieces are needed. If the pieces are larger than 16”x16”, trim down to size using a circular saw. Make sure the wood is secured with wood clamps before cutting.

4.2 Start with 120 grit sand paper, then 180, then 220 grit sandpaper on both pieces and

then remove the dust using air or brush. 4.3 If staining, stain one side of the wood, covering at least two corners, following

instructions given on the wood stain. Repeat for the second shelving piece. 4.4 Set both shelves aside to dry. Keep them in a place free of dust and debris. 4.5 Use wood clamps to secure the leg wood. Use the ruler to draw a line at 30”. Use the

circular saw to cut at the line.

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Note: If a different height is desired, draw the line at the length desired for the height of the table. Add ½ inch and that will be the total height of your table. 4.6 Lay the two pieces of wood on top of each other and verify the lengths are the same.

If not: 4.6.1 Place the longer piece on top and make sure one end is square.

4.6.2 Use the clamps to hold down the wood, verify it’s secure.

4.6.3 Mark on the top piece where the bottom piece ends, verify the line is square.

4.6.4 Use the circular saw to cut the ends.

4.6.5 Verify the ends are even, repeat if necessary. If there is only a small difference between the two, use a power sander.

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4.7 Measure 3” from the outside on both ends and draw a line down the center, as shown.

4.8 Lay the two pieces of leg wood on top of each other, and clamp to the table, allowing

for room to cut through both pieces. Make sure both pieces are aligned. 4.9 Use the circular saw to cut down the line.

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4.10 Measure 3” from the tableside of the wood and draw a line down the center.

4.11 Use the circular saw to cut down the line.

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4.12 Place the four legs on the table as shown and clamp together. Make sure all sides align. 4.12.1 If there are scratches or dings in the wood, place them closer to the right

side clamp. This will put imperfections in the wood at the bottom of the legs.

4.12.2 If the cuts made weren’t perfectly straight, place the straightest side on the table and after they are clamped, sand down the topside. Perfection on this isn’t imperative.

4.13 Measure 9” from the left side end of the legs and clamp the straight edge of the router

scrap wood on the line. This will offset the router for a cut at 12”. See below for clarification.

4.14 Use the router and 3/4" bit to make a slot through all legs.

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4.14.1 Position the router on the right side of the router scrap wood and start at .25" depth.

4.14.2 The slot should end at 1.25” deep. Use multiple passes, increasing depth approximately .25" each time.

4.15 Take one piece of shelving (the one to be the bottom shelf) and make sure that it fits in all of the slots.

4.16 Remove the clamps and place the legs aside. 4.17 Take the bottom shelf and clamp down to the table, leaving two opposite side corners

exposed.

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4.18 Place a straight piece of wood across the two corners. 4.19 Measure 3” away from the center piece of wood, and place the router scrap wood as

shown below. Clamp the router piece down and remove the piece of wood that was in the center. Measure the edges after clamping to verify the distance is still accurate.

4.20 Use the router to cut slots approximately 1.5” in on both corners. Stay along the

router wood.

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4.20.1 Start at .25" depth, and the slot should be cut all the way through the wood. Use multiple passes, increasing depth approximately .25" each time.

4.21 Grab two legs and slide them into the slots. Measure from the outside of the leg to the shelving. This is how much more needs to be removed.

4.22 Use that measurement from step 4.20.1 and mark the slot accordingly. 4.23 Use the router to cut up to the mark, and repeat step 4.20.1. It should sit flat. 4.24 Unclamp everything, and repeat steps 4.17 through 4.23 for the other two edges. 4.25 Take the top shelf and clamp down to the table. 4.26 For the mirror installation (optional)

4.26.1 Use the calipers, measure 2.125” and lock the calipers in place.

4.26.2 Use the sharp edge of the calipers to lightly mark the wood all around the perimeter. This is for the mirror placement.

4.26.3 Offset the router scrap wood 5.5” away from the edge of the shelf and clamp

it down.

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4.26.4 Set the router depth to .08” and router out alongside the router offset. Do not

cross the lines marked with the caliper.

4.26.5 Repeat steps 4.26.3 and 4.26.4 for the other edges, then remove the router scrap wood.

4.26.6 Use the router to empty out the interior of that square. Start at the center and move outward in a square pattern.

4.26.7 Use wood a wood chisel and hammer to square off the corners.

4.27 Flip the top shelf.

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4.28 Place a straight piece of wood across the two corners. 4.29 Measure 3” away from the center piece of wood, and place the straight block of wood

as shown below. Clamp that piece down and remove the piece of wood that was in the center.

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4.30 Use the router to cut slots approximately 3” in on both corners. Stay along the piece of wood that is clamped. 4.30.1 Keep this cut at only .25” deep.

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4.31 Grab two legs and slide them into the slots. Some of the top shelf corner should be sticking out. Draw a line across the exposed area on the top shelf.

4.32 Repeat steps 4.28 through 4.31 for the other corners. 4.33 Take the circular saw and cut off the corners of the topside where previously marked

in step 4.31. 4.34 Slide the legs into the bottom shelf, and place the top shelf on top. Make sure

everything is aligned. 4.35 Finish staining both the top and bottom shelf in the areas where they weren’t stained. 4.36 Set both shelves aside to dry. Keep them in a place free of dust and debris. 4.37 Sand down the legs with 120, 180 and 220 grit sand paper. 4.38 After the shelves are dry, cover inner slots on the bottom shelf with wood glue and

slide the legs in. Make sure to align the slots 4.39 Dab some glue on the bottom of the top shelf in the slots for the legs and place it on

the legs 4.40 Wipe excess wood glue wherever it can be seen. 4.41 Use large clamps or tie-downs to secure everything. 4.42 Allow to dry for 24 hours. 4.43 If desired, finish with polyurethane. 4.44 If installing the mirror, install that on top, using wood glue. This is done after to

prevent polyurethane from getting on the mirror. Allow to dry.