Recycled Wood Coffee Table

After replacing some of the fence palings with new ones at our house, I had some old ones left over, some of which were OK enough to warrant possible re-use.

At the same time, we were in need of a bigger and better coffee table for the lounge room, so an idea for a project was born. I will build a coffee table!

I began by sorting the boards, picking usable ones. There was lots of rough ones, split ones and rotten ones. Eventually, I found enough lengths that were good enough. At that point I got to work cutting them all to length.

At this point, I used a belt sander to try to remove as many of the splinters and rough surface as possible. If pieces weren’t fitting beside each other very well, I would plane them down with a hand plane, until they fitted better.

The boards, cut to size were then screwed to a couple of thicker pieces of timber, sourced from an old shipping pallet that was kicking around at home. Skirting boards were also screwed to the pallet timber.

There was a bit more planing and de-splintering done at this point, getting ready to apply a finish to the timber. Once everything was satisfactory, It was time to apply several coats of varnish. I think I applied 3 fairly thick coats over the course of a couple of days. I figure that should help hold the timber together a bit, and stop it from splintering.

With the table top sorted at this point, it was time to work on the legs. I used a length of 25mm square RHS steel. The joints were mitered by hand with an angle grinder, then tidied up the old-fashioned way, with a hand file. It would be nice to have a better method to cut things like this, but I can’t justify a bigger cutting method. A horizontal band saw, or a drop saw of some description would be really handy here.

Of course, the old-fashioned way requires lots of checking. Getting close, but still needs a little more work.

Here we can see the rough little welders square I made to hold the legs square. It wasn’t perfect, but was close enough for this task. I think I’ll have to try again for future projects. By allowing me to clamp the pieces together, it made it so much easier than it would have been if I had to take the pieces while they were loose.

It’s a little of a jump step again, but once I had the legs welded up as square as possible, and ground flush, I joined them together with a couple of pieces of 30mm angle iron. Tacking, and measuring  and adjusting , re-tacking, measuring .. etc…. I eventually got it pretty good. The legs weren’t exactly square, but it’s visually un-noticeable in the assembled product.

And then the legs were screwed to the pieces of timber at each end, holding it all together. Now, all I need to do is pull the legs off it, and paint them black. The paint has been purchased, so it shouldn’t be too long before I can call this one 100% complete.

And that’s it for this post. Sorry I haven’t been posting much lately, things get busy, and this year has really flown.  I hope you’ve enjoyed.

Bye for now.


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