8 9 7 4 Divider 3 /4” x 27 5/8” x 7 1/2” 3 2 10 5 Short Front & Back Panels (x2) 3 /4” x 16 1/4” x 7 1/2” 9 8 5 7 4 3 8 7 6 Bottom Panel Edge Banding (x2) 1 /8” x 50” x 3/4” 10 5 2 7 Side Panel Short Edge Banding (x4) 1 /8 ” x 8 1 /8 ” x 3 /4 ” 7 6 8 Side Panel Long Edge Banding (x3) 1 /8” x 27 5/8” x 3/4”
9 Long Front & Back Edge Banding (x2) 1 /8” x 33 1/2” x 3/4” 1 6 10 Divider Short Edge Banding (x2) 1 /8 ” x 7 3 /8 ” x 3 /4 ” 14 15 11 Fixed Top 3 /4” x 12” x 35” 16 14 12 Long Lift Top 3 /4” x 15 3/4” x 35”
15 13 Short Lift Top 3 /4” x 16 3/8” x 27 7/8”
16 15 16 14 14 Leg Rails (x4) 1 1/4” x 25 3/8” x 1 5/8”
15 Leg Stiles (x4) 1 1 /4 ” x 8 1 /2 ” x 1 5 /8 ”
14 16 Leg Stretchers (x3) 1 1/4” x 48 1/4” x 1 5/8”
15 Introduction
My wife and I love watching movies and TV together on the couch. So it’s no surprise we get a lot of use out of our living room. But that also means we like eating our meals in front of the TV and do computer work on the couch as well. A lift top coffee table would be the perfect addition to our home. Now we can eat in front of the TV by lifting the coffee table top to just the right height. No more sitting awkwardly on the floor and risk spilling drinks. The lift top also makes it more convenient to do work on the couch, while having the TV on. This coffee table features two lift tops, perfect for multiple members in the family, and a great fit for livingrooms with sectionals.
Making the case
The case is made from 3/4” walnut plywood, with 1/8” hardwood edgebanding. I will start by breaking down the plywood for the bottom and two side panels to their final sizes. And I will cut the rest of the pieces slightly oversized for easier handling.
1. Cut bottom panel down to its final size. 2. Use Rockler Crosscut Sled to cut side panels down to length. Then I will rip 1/8” pieces of hardwood to slightly more than 3/4” wide for edge banding. The strips will be cut longer than the length of the panels as well. I’ll flush up the strips to the panels later. The bottom panel will receive two pieces of edgebanding along the long edges, and the two side panels will both receive edge banding on three of the four edges. The strips will be attached to the panels using glue and bandy clamps.
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3. Use Microjig Grrripper to rip 1/8” hardwood into strips
4. Use Rockler glue brush applicator to apply glue along the plywood edges 5. Use medium Rockler Bandy Clamps to hold the edge banding down Once the glue has cured, I used a flush trim saw and a block plane to flush the edgebanding to the panels.
6. Use Suizan Flush Trim Saw to cut the edgebands to length 7. Use a block plane to flush up the edges of the trim to the top and bottom surfaces of the panel
After the edgebanding are flushed up, it’s time to cut the joinery. I used a 23/32” plywood router bit in my router to cut the dados. I pushed the two side panels against the bottom panel with their edges flush against each other. Then made the cuts with a single pass. This ensures the dados will line up.
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7/ 8”
8. Use Festool 1400 router and 23/32” router bit to cut the dados Next, I’m going to prepare for assembling the three sides of the case. I will be using dowels to add strength and help with alignment. First, I will place the side panels on the correct side of the bottom panel, then make sure the edges are flush against each other and clamp them down. This will ensure the panels will not move as I begin laying down the locations of the dowels. I will place the first dowel about 3/4” from the edge of the dado, and then the rest will be spaced roughly 3” apart. Once I’ve made the marks, I will use a square to strike a line through both panels at each of the marks. This will help to ensure the layout lines will line up perfectly between both panels.
10. Use a tape measure to space out the dowels 11. Use a square to strike a line through both panels, at each of the layout marks
Now, it’s time to set up the Rockler Doweling Jig. Since I am building the case out of 3/4” panels, I will use 3/8” dowels for this. The jig has a depth gauge engraved in the back to help me quickly set up the drill bit. Since the dowels are 1” long, I set up the depth to 1/2”, and then tightened the stop collar.
12. Use the depth gauge on the doweling jig to set up how deep to drill. Now just line up one of the reference marks on the jig to one of the layout lines we made to start drilling. It is straightforward for the bottom panel since the dowel holes will be drilled along the edge, the reference surface will be the top surface. But since we’ll be drilling into the top surface of the side panels, the reference surface will have to be the edge. So a longer clamp will be needed to clamp the jig to the work piece. This is where a vise will come in handy if you have one.
13. Using the Rockler One-Handed Bar Clamp to hold the jig to the bottom panel surface 14. Drill dowel hole using the 3/8” bit included in the Rockler 3/8” Doweling Jig
15. Use a vise or the Rockler Sure-foot F-style clamp to hold the doweling jig against the edge of the 16. Drill into the surface of the side panel. side panels Once all the dowel holes are drilled, it’s time to insert the dowels. I’ll start by applying a bead of glue along the dowel and inserting them into the holes along both edges of the bottom panel. Then apply glue along the bottom edges of both side panels and make sure to get some glue into the dowel holes as well. Then just bring the side panels and the bottom panel together. As long as you’ve taken the time to layout the reference lines previously, these panels should come together with ease.
17. Using the Rockler Glue Brush Applicator to apply glue along the dowel 18. Insert dowels along both edges of the bottom panel
19. Apply glue along the bottom edge of the side panels. Make sure to get glue into the dowel holes. 20. Bring the side panel and the bottom panel together. Then clamp the case together using clamps. Since only three panels are being glued together in this step, it’s important to use clamping squares to ensure everything is at 90º as the glue cures.
21. Using Rockler Sure-Foot Aluminum Bar Clamps to hold the side panels together to the bottom panel 22. Use the Rockler Clamp-It Square with Rockler Universal Fence Clamps to hold the panels square
After the glue has had some time to cure, I came back to cut the divider to size and cut the dados into the panel to match those on the bottom panel. I cut 3/4” x 1/4” notches on the bottom corners of the divider to allow the front and back edges to sit flush to the bottom panel edges. If you prefer the look of dados, feel free to cut the dado all the way through on the bottom panel. Then, just apply glue in the dado of the bottom panel and attach the divider. Once again, I used clamping squares to help ensure the piece is 90-degrees. I also used a long piece of offcut as a caul to help with spreading out the clamping pressure along the entire piece since I cannot get clamps to the middle of the panel. 8
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23. Cut 3/4” x 1/4” notches on the bottom corners of the divider
24. Attach the divider to the bottom panel using glue and clamps With the sides and the divider glued in place, I can measure between the dados and cut the front and back pieces to size. Then, just slide the pieces into the dados, apply glue, and clamp them up.
25. Use the Rockler Crosscut Sled to cut the front and back panels to size 26. Slide the long front and back panels into the dados
27. Slide the short front and back panels into place 28. Use glue and the Rockler Sure-Foot Aluminum Bar Clamps to attach everything together Making The Top
The top will consist of three separate panels made from 4/4 walnut hardwood. I chose not to use plywood for the top because the top will likely be used a lot, so I want it to be able to stand up to some level of abuse. I will also cut finger grooves to the bottom to help with holding the top when opening it, and I don’t want the plywood edges to show. To begin making the top panels, I will first cut the 4/4 lumber down to their rough lengths to make it easier to handle. Then I will run them through the jointer to flatten one face, and square up one edge. Next, I’ll run them through the planer to flatten the second face and bring the pieces down to their final thicknesses. Finally, I’ll run them through the table saw to square up the second edge, before gluing them up to form larger panels.
29. Use the Rockler Crosscut Sled to cut the lumber to their rough lengths 30. Use the jointer to flatten one face and square up one edge
31. Use the planer to flatten the second face and bring the pieces down to their final thicknesses 32. Square up 2nd edge on the table saw 33. Apply glue along the edges of the panels 34. Use Rockler Sure-foot Aluminum Bar Clamps for panel glue-up
After leaving the pieces glued up for a few hours, I came back later that day to cut them down to their final sizes. Then, I can attach them to the case. I started with the fixed top panel, which will be attached using dowels and glue. I placed it on top of the case, making sure all the sides are flush and then clamped it down. Then I used a square to mark the locations of the dowels and drilled the holes.
35. Cut panels down to their final size at the table saw 36. Position the fixed top on to the case 37. Layout position of dowels on both panels 38. Use the Rockler 3/8” Dowel Jig to drill holes into the bottom face of the top panel
39. Drill holes along the top edge of the side panels 40. Apply glue to all the parts and clamp everything together. Before attaching the two lift tops, I decided to use a 1/4” diameter bowl & tray bit in my router table to cut the finger grooves. I drew lines on the board to indicate the start and stop locations of the cut. After lining up the starting line, I’ll slowly lower the panel down into the bit, making sure to apply pressure into the fence, and downward into the table to avoid kickback. I find that lowering the panel down into the bit was less likely for me to get a kick back compared to just pushing the panel into the bit.
41. Install a 1/4” radius Bowl & Tray Bit on my Rockler Router Table 42. Lower the workpiece into the bit at the starting point, and end the cut at the end point.
Once the handles were cut, attaching it to the lift top mechanism was pretty straightforward, although not very easy to get it perfect. I used a piece of offcut as a spacer to help me place the mechanism so that its top surface was flush to the top edge of the case. I clamped it in place and secured it to the case using 3/4” screws. To secure the top panels to the mechanism, I had to measure the locations of one of the holes on each bracket, then transfer those measurements to the top panel. Then secure the rest of the screws. Every lift top mechanism will be different, so follow the supplier’s instructions for this.
43. Securing the lift top mechanism to the case 44. Secure lift top mechanism to the top panel Making The Legs The legs will consist of two rectangular assemblies, attached with three stretchers, all made from 8/4 solid walnut. Following the same process as that for the top panels, I milled the pieces to 1 1/4” thick, then ripped them to 1 5/8” wide, before finally cutting them to their final lengths.
45. Rip pieces to 1 5/8” wide 46. Use the Rockler Crosscut Sled to cut the pieces to their final lengths
I will once again use dowels for assembly. Each glue surface will receive two 3/8” dowels which will help with alignment as well as provide extra strength at the joints.
47. Drilling two 3/8” dowels on each glue surface 48. Glue all of the leg pieces together After allowing the glue to cure for a day, I came back the next day and used a rabbeting bit in my router to cut a 1/8” x 1/8” groove along the top edge of the legs. This is a choice I made to give separation between the legs and the case. This gives it a more modern aesthetic. After cutting the groove, I will use a 3/4” Forstner bit to drill a few recesses for receiving the Figure 8 Fasteners that I will use to attach the leg assembly to the case.
49. Cut 1/8” x 1/8” groove along the top edge of the leg assembly 50. Cutting recess for the figure 8 fasteners
51. Attach one end of the figure 8 fasteners to the leg assembly 52. Attach other end of the figure 8 fasteners to the bottom of the case.
