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hey guys I’m Tyler and welcome back to the channel. . .
If you guys readed last week’s website you know we made this beautiful live-edge maple farmhouse table and I kind of skipped over the fabrication of the legs. That is because I made these legs out of metal and they took quite a bit of time to fabricate and I wanted to go into a little bit more detail. If you guys wanted to make them out of wood, a little bit easier material to work with, you absolutely can. First order of operations was to break down all of the 2×4 1/8 wall tubing and I did this out in the garage using my portable band saw this website has been brought to you by saw blade com whose trades of 125 portable bandsaw I’ve been using to process all of the metal for these table legs the trajan 125 is an ultra portable bandsaw that’s perfect for small shops like mine or for job sites that you can get it up and out of the way when it is not in use 125 features a 110 variable speed motor so you can dial in that blade speed to exactly what you need it also has bearing guides on both sides of the blades and an adjustable rail guide this thing cuts miners like an absolute champ as you can obviously see in this website if you would like to find out more about the 125 or to make a purchase visit zombocom own lincoln the description below all the metal has been processed at this point and it’s in here and I picked up some riffraff off the street this guy Douglas from the retro weld YouTube channel he cleaned up the metal for me while I was processing it out there and we are actually going to be TIG welding this mild steel together and I have never taken welded before until this morning and Douglas he does all sorts of welding on his channel and he has recently gotten a lot more into the TIG welding process that’s what we’re gonna be doing on this table because it’s much cleaner there’s no spark so we can do it in the shop like I said it’s 8 degrees outside nice and warm right now just call yeah he’s from you’re from Memphis Tennessee right yeah they don’t they don’t do 8 degrees so let me talk to you a little bit about the setup itself for the leg and my thought process behind why it’s the way it is here is the Sketchup model of the leg assembly itself the tabletops gonna be right here and obviously the floor and right here we have a rectangle that’s going to be in the middle we’re going to weld that first and then put all of the different assemblies off of that hopefully we can keep everything nice and square to itself so we have a nice flat table to begin the welding we fired up my lincoln TIG 200 square wave TIG welder and those of you that actually know how to take probably laughed when I said I was going to be TIG welding all of this together we did start with the TIG welder and that I moved on later on in the build as you will see later once we got everything tacked together right now we are welding that in your rectangle together to make sure we get that nice and square to build our assembly off of I will get better at filming welding as time goes on I simply forgot to change my exposure to auto but I gotta say I’m pretty happy with these TIG welds since this was the first day I’ve ever touched a TIG torch once we had the inner rectangles of both leg assemblies completed I used a speed square and a flat reference surface to make sure the parts that I was assembling on either side of that new rectangle were as close to the same length as I could possibly get what I have found with metal is that any deviation adds a big effect later on after setting up a bit of a square jig on the assembly table I used my speed square to lay out the 45 degrees of either side of the leg assembly and then tacked it together with the TIG welder once the upper and lower portions of the leg assemblies were complete I laid them out with my jig and flat reference surface knowing that everything was square and then laid in the previously welded rectangles and then tacked them in place we did at least two tax on every joint on one side and then flip the assembly over and did the same thing on the other and like I mentioned before not everything was take welded once we had it all tacked together I moved it out into the garage where I could use the faster process of MIG welding I had a couple reasons for doing this one was those slight deviations that I mentioned I had some bigger gaps that I needed to fill and it was much much easier to do this with the MIG welder also there was just a lot of welding on here and it would have taken many many hours to do it with the TIG welder would have been good practice but I also wanted to get this done so that we could get the table in our house and the MIG welder worked out perfect I laid down the beads took it back into the shop on the flat surface and use a sanding disc to sand things down a little bit and then actually went back over those MIG welds with the TIG welder to make a nice wave pattern and then it was on to the wire wheel to buff up those welds nice and shiny and clean off any rust that had developed on the steel as it was waiting for me to assemble these for the finish I started with a coat of self-etching primer and then finished it up with a several coats of semi-gloss black enamel once the paint had cured I brought it back into the shop and laid out where I needed the holes to attach the tabletop to the leg assembly people have asked me already in the tabletop website what I did to allow for expansion of the tabletop and what I did was drilled the holes much oversized and put the bolts in the middle of those holes so that the table can expand and contract with no issues I’m not sure if this step is absolutely necessary because the felt pads that we put on there might be adequate but I didn’t want the open ends of the tubing sliding across the floor so I made some maple pads that I recessed drilled and then tapped into the leg assembly and bolted these in place to act as a cap for the felt pads to be fastened to then cut in fasten those felt pads in place and these are just a big square pad that I was able to get at the Home Center laid the legs out on the tabletop upside down obviously in positions that would allow me to sit with my knees comfortably extended while sitting on the chair and then I laid out lock washers and flat washers with the bolts that we need to go through the leg assembly and then through the mounting pad of the angle well there we are guys that is a wrap I hope you enjoyed this website these legs are going absolutely nowhere for generations I will probably be able to pass these on to my kids kids and even further we might have to replace a table top as it gets damaged but these legs are going nowhere solid as a rock you can cut your steak and your water doesn t move when it sit right next yeah fantastic if you guys enjoyed this website please hammer that thumbs up button helps us out a ton on DIY Tyler and you guys have a good one.