Eight Foot Extension Table -- Alder

My customer brought a set of plans for an extension/drop leaf table he wants.  The  table expands from 32x42 up to 42x96 with three Duncan-Phyfe style legs.   The plans are poorly documented and have some errors in the drawing, but I will make the necessary modifications and get rolling on this right away.  The Duncan-Phyfe style will be modified to a more practical design. 

Three boards glued up for each foot..the center one notched 1in deep on the table saw before glueing.  Makes for a clean, accurate mortise.

The three leg sections are almost done, Using the jointer to nudge the vertical boards to fit the mortise.

Next, between dog training sessions, I will shape the foot ends, route edges and sand.

Define the 'toe' with TS cut and bandsaw the curve.   Mark the foot relief with gauge and bandsaw it out.

completed foot

3 Feb.  After a busy weekend at the NADAC agility trial with my pal Jack the wonder dog, I managed to get the leg assemblies glued and screwed.  Next is to pick up a little maple for the extension slides tonight.

The extension assembly worked better than I imagined.   I cut out a 1/2 inch recess in maple to attach the 100lb, full-extension drawer glides.  They slide very smoothly and are rock solid with no support over the full six feet.  With three legs under them my customer can dance on it ;o). Still have 12 inch extensions to add to each end for the drop-leaves.

I've spent what spare minutes I have lately getting the top sections glued up.  Using biscuits to keep adjacent boards aligned will reduce the amount of planing.

Four top sections glued

Spent two days flattening and sanding the seven top sections.

Rule Joints cut

Complex structure almost complete

Drilling holes for alignment pins

Truing up the edges 

Corners radiused and ready to finish

Began finishing today... I had some flaws in one of the leaf sections and decided rather than try to repair them, I could just make an inlay.  This table will be in a cabin on the Kenai river, so what better to inlay than salmon?

Inlay

 

The three leaves with second coat

Main table with 3rd coat (odd lighting)

3/17   Made the 12 leaf pins and installed them on St Patrick's Day, topped it with a coat of wax and ready to deliver!

3/20  Delivery day

At the cabin on Kenai River