Serving Tray
Serving Tray
by Rob Brown
Add versatility to your outdoor living space with a handcrafted wooden tray that transforms your ottoman into a functional serving surface. Customize your project with a visit to your local Home Hardware or Home Hardware Building Centre location to choose a wood finish and cabinet hardware to match your décor.
What you'll need
Tools
- jointer
- planer
- sander 1340-017
- drill 1239-210
- table saw 1346-683
- sanding block 1061-282
- clamps 1022-480
Materials
- 1" thick solid lumber - 6" wide x 42" long
- 1" thick solid lumber - 5" wide x 75" long
- carpenter glue 2020-173
- masking tape 1670-686
- polyurethane 1877-026
- cabinet handles 2321-311
Here's how
- Break out four sides and cut to final thickness and width (shown: 15" x 25").
- Break out the slats and dress them to final thickness.
- Cut mitres on the one end of each side.
- Mark for length and cut mitre on other end of each piece. (photo 1)
- Machine 1/4" wide groove in sides to accept bottom slats. (photo 2)
- Determine exact dimensions of slats, taking depth of grooves into account. (photo 3)
- Cut the slats to final size, allowing 1/4" between slats.
- Machine rabbet around outer edge of slats. (photo 4)
- Sand parts and break edges.
- With four sides face down on a flat surface and butted end-to-end, apply ample masking tape across the joints.
- Do a dry assembly and make necessary adjustments. (photo 5)
- Apply glue to mitres, grooves, and slat tenons. Assemble tray. (photo 6)
- When dry, flush any corners, sand outer edges, and break sharp edges.
- Drill for handles.
- Apply 3 coats of finish.
- Attach handles.
Mitred Corners With the sides cut to width and thickness, mitre the corners, ending at the finished length. |  |
Slightly Proud When making the first cut for the 1/4" groove, ensure the top of the groove is positioned slightly above the slat when both parts are sitting on a flat surface. | |
Exact Measurements Using a straight edge, measure the length of the long and short grooves. Make the slats finish about 1/16" shy of these dimensions, all the way around the tray. Plan for a 1/4" wide gap between the slats. | |
Run the Rabbets Machine the rabbets in the underside of the slats. Be sure to machine only the edges that will finish on the outer perimeter. | |
| Dry Assembly A dry run is crucial to work out any kinks, and to double-check that everything fits. With tape on the outer mitred joints, fold the sides together and insert the slats, bringing the last corner together with the slats in place. | |
| Gluing Mitres Add a very light coating of glue on the mitred ends and rub into the wood. After waiting a few minutes, apply more glue and continue the assembly. The first light coat of glue helps fill the end grain pores so the joint isn't too dry. |
Rob Brown designs and builds custom furniture and is editor of Canadian Woodworking and Home Improvement magazine.
