WOODWORKS: ADVANCED PROJECT

SNACK BAR AND STOOLS

A stylish, all-purpose table that goes great with a pair of sturdy stools. This versatile table is perfect for schoolwork, small projects and board games.

If you haven’t yet built your first table and chair set, you could do a lot worse than starting with this group. The simple lines of both pieces offer a
pleasing style, but they’ll also challenge you to be very precise with all your cuts and joinery. Meant for those with advanced skills, these projects
will develop your skills in cutting compound angles, making mortise-and-tenon joints with a router and a table saw, making router-cut curves with a
special jig, and more. And after you build these pieces, you’ll learn more about applying stains and finishes to enhance the wood’s natural beauty
and ensure that it’s well protected.

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TOOLS REQUIRED
Hand Tools Power Tools Miscellaneous
– Handsaw – Table saw – Safety glasses – Minwax® Wood Finish™
– Wood rasp and file – Bandsaw – 120-, 150- and 220-grit Stain Brush or other good
– Sanding block – Miter saw sandpaper quality, natural bristle
– Bar clamps – Plunge router – Clean, lint-free cloths brush (for oil-based stains
– Vise – Belt and orbital sanders – Respirator and finishes)
– Spokeshave or drum sander – Gloves for finishing – Minwax® Polycrylic® Brush
– Mineral spirits (for oil- or other good quality, syn-
based finishes) thetic bristle brush (for water-
– Water-filled metal container based stains and finishes)
with tight-fitting lid – Carpenter’s glue
– Double-faced tape
SHOPPING LIST CUTTING LIST
Table Table
Item Quantity Key Part Pcs. Thickness Width x Length Notes
8/4 legs 1 pc. 7-1/2" x 36-1/2" A Leg 4 1-3/4" 1-3/4" x 36-1/8"
4/4 rails 1 pc. 7-1/2" x 60" B Upper rail-end 2 3/4" 2" x 22-1/2" 3/8" x 1-1/4" x 1" tenon
5/4 slats 4 pcs. 7" x 36"; 1 pc. 2" x 36" C Upper rail-side 2 3/4" 2" x 34-1/2" 3/8" x 1-1/4" x 1" tenon
5/4 top 4 pcs. 6-1/4" x 36-1/2" D Lower rail-end 2 3/4" 3" x 22-1/2" 3/8" x 2-1/4" x 1" tenon
1-1/4" flathead E Lower rail-side 2 3/4" 3" x 34-1/2" 3/8" x 2-1/4" x 1" tenon
woodscrews 45 F Stretcher 1 3/4" 3/4" x 2" x 21-1/2"
G Slat 11 1" 1-13/16" x 36"
Stool (material for one stool) H End slat 2 1" 1-3/4" x 32-3/8"
Item Quantity J Top 1 1" 24" x 36"
5/4 legs, stretcher 1 pc. 4" x 24"; 1 pc. 4" x 36" Buttons 12, see Fig. 1 for dimensions
5/4 seat 1 pc. 11-1/2" x 11-1/2" Plugs 30, 3/8" dia., store-bought or made with a plug cutter
4/4 rails, tenons 1 pc. 5" x 36"
Stool
1-1/4" flathead
Key Part Pcs. Thickness Width x Length Notes
woodscrews 4
A Leg 4 1-1/4" 1-1/4" x 23-1/16" cut both ends at
Recommended Wood: Oak 85º compound angle
Alternate Wood: Birch B Upper rail 4 9/16" 3-1/2" x 6-5/8" 5º ends
C Lower rail 4 9/16" 1-1/4" x 7-1/32" 5º ends
D Stretcher 4 7/8" 2" x 9-3/32" mark exact length
approx. against actual leg /rail
assembly
E Seat 1 1" 11-1/4" x 11-1/4" 1/2" radius corners
Loose tenons 24, sized to fit their respective mortises
WOOD FINISHING Buttons 4, see Fig. 1 for dimensions
PRODUCTS
Recommended Finish
Table Stool Alternate Finish
Prep: Minwax® Pre-Stain Wood Prep: Minwax® Pre-Stain Wood Prep: Minwax® Pre-Stain Wood
Conditioner (if using soft or Conditioner (if using soft or Conditioner (if using soft or
porous wood) porous wood) porous wood)
Stain: Top and slats – Minwax® Wood Stain: Top – Minwax® Wood Finish™ Stain/ Minwax® Polyshades® Classic
Finish™ Sedona Red* Sedona Red* Finish: Oak Satin (or your choice of
Legs – Minwax® Wood Finish™ Legs – Minwax® Wood Finish™ 9 Minwax® Polyshades® colors
Golden Oak* Golden Oak* in satin or gloss)
Finish: Minwax® Helmsman® Spar Finish: Minwax® Helmsman® Spar
Urethane Satin Urethane Satin
*Or your choice of 20 Minwax® Wood Finish™ Stain colors.

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BEFORE YOU BEGIN 10. Dry-assemble the table, using clamps to snug up all the joints. Lay
Good craftsmanship begins and ends with good work habits, so make stretcher material in position, mark it and cut to fit between the rails.
the following steps part of your routine workshop practice. If you have
any doubts or questions about how to proceed with a project, always 11. If everything fits in the dry-assembly, start gluing. Begin with
discuss them with your shop instructor. one long side, then the other. When these are dry, glue the end rails
• Carefully and fully review plans and instructions before putting a and clamp snug. Check for square by measuring the diagonals and
tool to the project lumber. adjust clamp compression as needed to produce right angles. Screw
• Work sensibly and safely. Wear safety goggles when doing work the stretcher in place, and sand the plugs smooth.
that creates flying chips and sawdust; wear the appropriate
respirator whenever making sawdust or working with thinners 12. Glue together the boards for the top (J), then smooth the panel as
or other solvents. needed with belt and orbital sanders.
• At the end of every work session, clean up your shop area and put
away all portable tools. 13. Cut the top to size then notch the corners using the table saw tech-
nique shown in Fig. 5. It requires attaching a tall fence to the miter
CUTTING AND ASSEMBLY gauge and clamping the assembled top to it. A spacer block clamped
PROCEDURE to the fence lets the off-cuts fall safely away from the blade.

Constructing the Table 14. Insert the buttons into the kerfs on the upper rails. Test-fit the
1. Cut legs and rails (A, B, C, D, E) to size as shown in Fig. 1. The top on the table base, and drill screw holes through the buttons and
lengths given include the tenons. into the top. Use a stop on your drill bit to prevent accidentally drilling
all the way through.
Woodworker’s Tip: Make one extra leg as a test piece for your
router mortising, and a couple of extra rails as test pieces for 15. Cut the slats (G, H) to size. Drill them for plugs, then drill screw
cutting tenons. These extra parts don’t have to be full length. clearance holes in each. Sand and ease all edges.

2. Lay out the mortise locations on the legs. Stand up the legs and 16. Lay out the slats on the rails, using shims to keep the spacing iden-
double check to make sure there are two rights and two lefts (Fig. 2). tical. Drill pilot holes through the clearance holes. Screw on the slats,
glue in the plugs and then cut and sand the plugs flush.
3. Cut the leg mortises, using a plunge router. If you clamp a couple
of pieces together, they become a more stable surface for the base of Woodworker’s Tip: If you plan to finish the slats a different
the router. color from the legs, it’s easier to drill holes in the bottom of the
rails and screw on the slats from below. This way, the slats can be
4. Use a plunge router to cut slots in the upper rails for the stained before being attached. Be sure to drill the holes before
12 tabletop buttons. cutting the curves in the lower rails.

5. Cut tenons on the ends of the rails. Use the miter gauge and table
Constructing the Stool
saw set up with a dado blade. You can use the saw fence for quick
1. Cut the legs, rails and stretchers (A, B, C, D) to width and rough
repeatability on these cuts. To do that safely, you must clamp a
length, then cut the compound angled ends on the legs. Notice that the
block to the fence just in front of the dado blade. Then set the fence
edges of the rails and stretchers are cut at a 5º bevel. Don’t cut the
to the appropriate position, using the block as the stop that determines
angled ends on the rails and stretchers yet.
the length of the tenon. Use your test rails to set the height of the
dado blade, and test the tenon for a sliding fit in the mortises.
Woodworkers Tip: Use one piece for both upper and lower rails,
and rip to make the two pieces. This will give you a good grain
6. Round the corners of the tenons with a rasp and file, and miter the
match. Also, it’s a smart idea to have an extra leg and a couple of
ends of the tenons.
rail pieces to set up and practice your mortises. They can be cut
from 2x4 lumber so you don’t waste good wood.
7. Use the patterns shown in Fig. 3 to make template jigs for the curves
on the lower rails. Make the template out of 1/4" plywood and fasten a
2. Lay out the locations for the mortises as shown in Figs. 6 and 7, then
guide handle to it as shown in Fig. 4.
prop up all four legs to make sure the mortises face each other when
the legs are in their proper orientation.
8. Cut the curves in the lower rails on a shaper or table-mounted
router. Secure the work pieces to the jigs with double-faced tape.
3. Mortise the legs, using a plunge router fitted with an edge guide. It
helps to clamp a couple legs together so the router has a wider surface
9. Lay out and drill the screws and plug holes on the two lower side
to slide on.
rails (E). They should be centered on the length.

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4. Trim the ends of the rails, using a stop on the fence of your miter FINISHING TIPS
saw to be sure each set of four is exactly the same length. Cut the ends • Test the stains and finishes you are planning to use on scraps of
of each of the stretchers to the same 5º angle. wood. On the back of the scrap, mark the stain/finish combination
and the type of wood. Allow all samples to dry thoroughly before
5. Mortise the ends of the rails and stretchers by clamping them side-by- making your final finish selection. Save your samples for quick
side vertically in a vise, with the ends flush. Clamp a block next to them reference on future projects.
to help support the base of the router. Then plunge-rout the mortises. • All stains and finishes must be allowed to dry thoroughly between
coats. Remember that drying times can vary due to humidity and
6. Clamp the rails between a pair of legs, put a stretcher in position, other climatic conditions.
then mark it for the final cut as shown in Fig. 9. Make the other three • If you have some leftover stain or finish, wipe the can rim so that
stretchers to this length as well. stain or finish in the rim won’t dry out and prevent the lid from
forming a tight seal.
7. Make the loose tenons as shown in Fig. 6. Begin by machining the • Brushes used for oil-based finishes must be cleaned with
stock to the appropriate thickness for a sliding fit in the mortises you mineral spirits.
routed. Then rip the material to width, and with a round-over bit
in the router table, make two passes to round the edges. Recommended Finish
16. Apply the Minwax® Wood Finish™ you’ve chosen to the interior
8. Dry-assemble two legs with the rails and stretchers in place to test surfaces using a natural bristle brush and a clean, lint-free cloth follow-
your joints. ing the directions on the can. The brush will help you get the stain into
the many inside corners and other tight spots. Allow the Wood Finish™
9. Use the dimensions shown in Fig. 8 to lay out the curve at the to set for about 5 to 15 minutes, then wipe off any excess. To achieve a
bottom of the stretchers (D). Cut them on the bandsaw with the table deeper color, you may apply a second coat after 4 to 6 hours, repeating
tilted 5º; smooth the curve with a spokeshave or drum sander. the application directions for the first coat. Allow the stain to dry for
24 hours before applying the protective clear finish.
10. Make four buttons to the dimensions shown in Fig. 6. Cut mortises
on the inside surface of the upper rails for the buttons that secure the Woodworker’s Tip: When wiping off stain, make certain that
seat to the frame. your last wipe with the cloth goes with the grain of the wood.

11. Next, cut mitered ends on the tenons as shown in Fig. 7. These 17. Using a good quality, natural bristle brush, apply Minwax®
angles don’t have to be exact, so a handsaw or bandsaw is an easy Helmsman® Spar Urethane Satin following the directions on the can.
way to cut them. Allow the piece to dry for at least 6 hours before applying the second coat.

12. Do all finish sanding and round over all edges. 18. The following day, sand all surfaces very lightly with 220-grit or
finer sandpaper using with-the-grain strokes. Dust off and wipe all
13. Glue up two legs with their stretcher and rails. Keep the assembly surfaces with a cloth lightly dampened with mineral spirits. Apply the
flat. You may want to use angled blocks to help keep the clamps from second coat of Helmsman® Spar Urethane. For added protection,
slipping, as shown in Fig. 10. Use a 1"-wide block to keep the upper apply a third coat to the table top.
and lower rails properly spaced.
Alternate Finish
14. Glue the other pair of legs, and when they’re dry, glue the two 19. Prepare the wood as you did in the recommended finish.
assemblies together. This should be done with the stool sitting upright
on a flat surface. 20. Apply Minwax® Polyshades® following the directions on the
can. Use a good quality, natural bristle brush suitable for use with
15. Cut the seat to size, round the corners, then round over the edges. polyurethane. Stir the can contents thoroughly before starting and
Sand and attach the buttons that hold it to the rails with the woodscrews. periodically repeat stirring during your work session. Allow the first
coat to dry overnight.
NOTE: If you decide to two-tone stain, it’s best to stain and finish the
seat and legs separately, then assemble. 21. The next day, rub all surfaces with a fine steel wool (grade 000 or
finer) using with-the-grain strokes. Dust off and wipe all surfaces with a
STAINING AND FINISHING cloth dampened with mineral spirits. Apply a second coat of Polyshades®
Woodworker’s Tip: Though you may be tempted to cut short and set the pieces aside to cure overnight. To achieve a deeper color,
your sanding, preparation and application time, don’t do it. These you may apply a third coat after 4 to 6 hours, repeating the application
tasks are very important steps in obtaining a high-quality finish. directions. Allow the project to cure for several days before using it.
Remember, it is the finish, just as much as the fit and smoothness
of the parts that will have great bearing on how people judge your Woodworker’s Tip: If you achieve the desired color on the
craftsmanship. To ensure an excellent result, follow the steps first or second coats of Polyshades®, simply apply a clear coat of
listed in this section and also the instructions the finish manu- Minwax® Fast-Drying Polyurethane or Minwax® Wipe-On Poly
facturer puts on its products. for added protection.
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PRODUCT SAFETY WARNING: Contains Alkyl propanols, ethylene glycol, n-methyl pyrroli-
For your safety and the safety of those you work with, always read the done. VAPOR HARMFUL. Use only with adequate ventilation. To avoid
safety warnings, which manufacturers print on their labels, and follow overexposure, open windows and doors or use other means to ensure
them to the letter. Typical safety advice and instructions will contain fresh air entry during application and drying. If you experience eye
information such as the following: watering, headaches, or dizziness, increase fresh air, or wear respira-
tory protection (NIOSH approved), or leave the area. Avoid contact with
WARNING! Removal of old paint by sanding, scraping or other means eyes and skin. Wash hands after using. Keep container closed when not
may generate dust or fumes that contain lead. Exposure to lead dust or in use. Do not transfer contents to other containers for storage.
fumes may cause brain damage or other adverse health effects, espe-
cially in children or pregnant women. Controlling exposure to lead or DO NOT TAKE INTERNALLY.
other hazardous substances requires the use of proper protective FIRST AID: In case of eye contact, flush thoroughly with large amounts
equipment, such as properly fitted respirator (NIOSH approved) and of water for 15 minutes and get medical attention. For skin contact,
proper containment and cleanup. For more information, call the wash thoroughly with soap and water. In case of respiratory difficulty,
National Lead Informations Center at 1-800-424-LEAD (in US) or provide fresh air and call physician. If swallowed, call Poison Control
contact your local health authority. Center, hospital emergency room, or physician immediately.

When using oil-based wood finishing products: DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.
CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS. Contents Contains solvents which can cause permanent brain and nervous
are COMBUSTIBLE. Keep away from heat and open flame. VAPOR system damage. Intentional misuse by deliberately concentrating
HARMFUL. Use only with adequate ventilation. To avoid overexposure, and inhaling contents may be harmful or fatal.
open windows and doors or use other means to ensure fresh air entry WARNING: This product contains a chemical known to the
during application and drying. If you experience eye watering, State of California to cause cancer and birth defects or other
headaches, or dizziness, increase fresh air, or wear respiratory protec- reproductive harm.
tion (NIOSH approved), or leave the area. Avoid contact with eyes and KEEP OUT OF REACH OF CHILDREN.
skin. Wash hands after using. Keep container closed when not in use.
Do not transfer contents to other containers for storage. SAFE DISPOSAL OF RAGS AND WASTE.
Please be mindful of the safe way to dispose of rags and other waste.
FIRST AID: In case of eye contact, flush thoroughly with large amounts Rags, steel wool and other waste products soaked with oil finishes or
of water for 15 minutes and get medical attention. For skin contact, solvents may spontaneously catch fire if improperly discarded. Place
wash thoroughly with soap and water. In case of respiratory difficulty, rags, steel wool and other waste immediately after use in a water-filled
provide fresh air and call physician. If swallowed, do not induce metal container. Tightly seal and dispose of the waste materials in
vomiting. Call Poison Control Center, hospital emergency room, or accordance with local trash removal regulations. Be sure to keep the
physician immediately. waste out of reach of children.
NOTICE: Reports have associated repeated and prolonged occupa-
tional exposure to solvents with permanent brain and nervous system
damage. Intentional misuse by deliberately concentrating and inhaling
contents may be harmful or fatal.
WARNING: This product contains a chemical known to the
State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH
OF CHILDREN.

When using water-based wood finishing products:

CAUTIONS: Use Only With Adequate Ventilation. To avoid overexpo-
sure, open windows and doors or use other means to ensure fresh air
entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory protec-
tion (NIOSH approved), or leave the area. Avoid contact with eyes and
skin. Wash hands after using. Keep container closed when not in use.
Do not transfer contents to other containers for storage.

FIRST AID: In case of eye contact, flush thoroughly with large amounts
of water. Get medical attention if irritation persists. If swallowed, get
medical attention immediately.

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FIG 1. TABLE DETAILS

TOP
1" X 24" X 36"

J
ROUT SLOT FOR BUTTON
113/16"
ROUT OR PLANE 1/8" TENON
RADIUS ON TOP OF LEG 3/8" X 11/4" X 1" L.

11/2"
UPPER RAIL BUTTON
3/4" X 2" X 341/2"
C
B UPPER RAIL
3/4" X 2" X 221/2"

COUNTERBORE FOR LEG

SCREW AND PLUG 13/4" SQ. X 361/8"

ROUT OR PLANE WOOD PLUG END SLAT

1/16" CHAMFER H 1" X 13/4" X 323/8"
ON ALL EDGES SLAT
G 1" X 113/16" X 36"
1/16" (TYP)

LOWER RAIL LOWER RAIL

3/4" X
3" X 341/2" F A 3/4" X
3" X 221/2"

D
33/8"
JOIN STRETCHER TO
LOWER RAILS WITH E
SCREWS AND PLUGS. 1"
TWO EACH END
TENON 3"
3/8" X 21/4" X 1" L.

MITER ENDS OF TENONS

AT 45˚ (SEE DETAIL.)

BUTTON DETAIL

1/4"
1/2" 1/4"

1" 11/4"

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FIG 2. MORTISE AND TENON DETAIL

TOP SECTION
CL

RAIL

CENTER TENON
ON LEG AND RAIL

LEG CL

SIDE SECTION 1"

TOP

CL
11/2"
11/4" CENTER TENON
ON HEIGHT OF RAIL

FIG 3. CUTTING TEMPLATE OF LOWER RAILS

2"

211/2"

3"

1"

2"

331/2"

3"

1"

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FIG 4. ROUTING A CURVE FIG 5. NOTCHING THE TOP

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FIG 6. STOOL DETAILS

111/4"
111/4"
1/2" RADIUS
TOP E

BUTTON

ROUT SLOT FOR BUTTON

UPPER RAIL
C

231/16" LOWER RAIL

A BEVEL ALL RAIL AND

STRETCHER EDGES 85˚

ROUT MORTISE
FOR LOOSE TENON
D

12"
85˚ STRETCHER

MITER END OF LOOSE TENON BUTTON DETAIL

85˚ AT 45˚ (SEE FIG 7.)

1/4"
1/2" 1/4"

1" 11/4"

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FIG 7. ELEVATION AND SECTIONS

2: ELEVATION AND SECTIONS

1" SECTION THROUGH LEG
6"
AND UPPER RAILS
31/2"
9/16"
1/4"

3/16"

1"
11/4"

24"
11/4" SECTION" THROUGH LEG
AND STRETCHERS

7/8"
2"
1/4"
3/16"
7/8"
71/4"

85˚
12"

FIG 8. DIMENSIONS FOR ALL RAILS

6"

31/2"

1"
11/4"

2"
7/8"

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FIG 9. MARKING THE STRETCHER FIG 10. ANGLED CLAMPING

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