The Console Table Build

My honey-do list usually starts out the same. My wife will ask if I can make something for her and then asks how much it will cost in wood. I told her it would probably run around $60 so we headed to Home Depot and bought some white pine boards.

I bought a few 1″ x 10″ x 6′ to use for the legs. One 1″ x 10″ cut in half and ripped into 2 1/2″ wide segments would yield me two legs. After I laminated three of the boards, I sized them to 2 1/4″ square and then turned them on the lathe. I looked at the picture she gave me but I turned the leg from feel of what I thought it looked liked. When I was done, we both decided the bottom part of the leg looked too “boxy” so I decided to turn another leg.

The second leg turned out better than the first. When I threw a picture of both legs onto instagram, one of my followers said that he liked the bottom of the leg on right but liked the top of the leg on the left. I agreed so I refined the leg so the ball of the leg looked more like a ball and not a fat lazy bead.

After refining the leg, I made five more freehand. I’m by no means a master wood turner. In fact, my wood turning is passable at best. The only lesson I’ve ever taken on wood turning is watching The Woodwright’s Shop over the years. I take a ruler, a parting tool, and some calipers and try to make the sixth one to look like the first. In the end, I think the legs came out pretty good.

My wife wanted table to be fourteen inches wide by five feet long so I laid the legs on the top and decided the dimensions of each part of the frame.

After cutting out all the parts of the frame, I attached them to the legs with pocket hole joinery. This is a simple table made from construction grade material so I wasn’t in the mood to start cutting a bunch of mortises for mortise and tenon joinery. Sorry.

I sized and glued the bottom shelf to the lower frame. Ideally this would be best suited for plywood due to the expansion and contraction of the wood however, after studying the original picture, this is how the table my wife wanted was built so I went ahead and made it the same way. Eventually there will be a nice crack in the middle of the shelf, but that will just add to the farmhouse look.

I made the drawers as simple as possible as well. I planed down some of the pine to 1/2″ thick and made the sides with rabbeted joinery and a 1/4″ plywood bottom. I then simply glued and nailed a drawer front to the box.

In the end, this is how the table came out. Not bad for a weekend build. My wife will finish the table with some sort of weathered look stain. I’m happy with it and it’s one less thing off of my honey-do list.

Making a Replacement Handle for a Knew Concepts Saw

Back in October I bought a Knew Concepts saw at the Woodworking in America marketplace in Covington, KY. I always heard that the biggest complaint about the saws were that they came with a cheap handle that didn’t fit with the looks of the saw. I was willing to live with the handle for awhile until I had the time to make a replacement, but I did think it was uncomfortable. In fact, the more I held it, the more I hated it. There is a company on the internet who sells replacement handles for Knew Concept saws out of exotic wood, but those handles are thicker than the original. I don’t want something that is thicker, I want a handle that is thinner.

Then a few weeks ago, I saw this antique knife sharpener in an antique store. I didn’t care about the knife sharpener part. What interested me was the feel of the handle. I knew as soon as I grabbed it, it would make a great replacement for my Knew Concepts saw. So, I ended up buying the knife sharpener simply to use the handle as a template.

In order to make a new handle, I needed to take the old one off. The handle on the Knew Concepts saw had a small little cotter pin that needed to be removed. Unfortunately, I didn’t have a special tool to get the thing out, so I had to do it the old fashioned way.

I basically had to trash the handle in order to get it off. I drilled through cotter pin and tore into the handle to remove all the wood around the pin in order to grab the pin out with a pair of pliers.

Now needed a piece of wood nice enough to make a new handle. I bought a slab of apple from a guy on eBay and cut off about 10″ from the end.

I then milled the piece into two 1″ pieces and a third piece to 1/2″

I took one of the 1″ thick slabs and milled 1″ square blanks. Each blank will be used as handles for something or another.

I attached the apple blank into my lathe and turned a new handle using the knife sharpener handle as a template. The handle is nothing fancy, but it is comfortable to hold.

The handle is turned and sanded. The end of the handle where the ferrule goes is 5/8″ in diameter because the inside of the copper fitting I used to be the ferrule of the handle is 5/8″ in diameter.

I used a 5/8″ socket wrench while the handle was on the lathe and used the wrench as a gauge to know when to stop when I turned it to size with my parting tool. As you can see, the fitting fits perfectly over the ferrule end of my handle. I trimmed the extra part of the copper fitting flush to the end of the handle with a hack saw.

The biggest challenge in making the handle fit, is cutting the mortise slot into the end. I found the center of the handle and carefully drilled an 1/8″ hole straight down the shaft. I then took an 1/8″ chisel and cut a rectangular mortise down the hole. Carefully checking every few minutes, I took my time and pared away the wood so that the entire tang of the saw would eventually fit snuggly into the handle.

Once everything fit well, I figured out where the hole of the tang lined up with the copper ferrule and drilled an 1/8″ hole through the copper. A 16 penny nail fits perfectly into the 1/8″ hole to act as the pin. I cut the nail to size and hammered it with a ball peen hammer to act as a rivet. I also used some JB Weld in the hole to give everything a bit more strength.

With a little oil on the handle, here it is. A Knew Concepts with a much more comfortable handle ready for years of use.