{"id":40048,"date":"2019-12-05T09:18:31","date_gmt":"2019-12-05T07:18:31","guid":{"rendered":"https:\/\/www.lion-test-sites.co.za\/mica-new\/?p=40048"},"modified":"2019-12-05T09:18:33","modified_gmt":"2019-12-05T07:18:33","slug":"butlers-tray-table","status":"publish","type":"post","link":"https:\/\/www.lion-test-sites.co.za\/mica-new\/butlers-tray-table\/","title":{"rendered":"Butler\u2019s 2-in-1 Tray-Table"},"content":{"rendered":"\n

This\nhandy butler\u2019s tray doubles as a tray and also as a folding table, to be folded\naway when not needed.<\/p>\n\n\n\n

Note\nthat the Perspex is optional, but it does provide a very easy-to-clean surface\nin case of spills.<\/p>\n\n\n\n

Materials:<\/strong><\/p>\n\n\n\n

*Perspex\n one 600x600mm sheet cut to 305x505mm (tray base)<\/p>\n\n\n\n

Hardboard\n one sheet 1220x610mm, cut to 305x505mm (tray base) and 1 piece to 525x325mm\n(table base)<\/p>\n\n\n\n

Hardboard\n one sheet 1220x610mm, cut to 305x505mm (tray base) and 1 piece to 525x325mm\n(table base)<\/p>\n\n\n\n

Meranti:\n22x44x1.83m three lengths cut to 4 legs, each 700mm long, angled at approximately\n30\u00b0 at each end, parallel; 1 cross-brace 470mm long; table base 2 lengths\nof 305mm and 2 lengths of 505mm<\/p>\n\n\n\n

Meranti\n one length 12x96mm ripped lengthwise into 2 strips each 12×44, cut to 2 table\nsides (550mm long) and 2 ends (each 326mm), and 2 tray sides (each 525mm) and 2\ntray ends (each 298mm long). (Leftover strip is used to secure the tray base to\nits frame)<\/p>\n\n\n\n

Bevel\nbeading 10x19mm 2 lengths of 1.8m inner tray frame, cut to 4 lengths of\n305mm and 4 lengths of 505mm each end cat at an angle of 10\u00b0 and trimmed to\nfit within the outer frame<\/p>\n\n\n\n

Two\nsliding bolts (to lock the table legs in position) 50mm<\/p>\n\n\n\n

Two\nbrass hinges 50mm<\/p>\n\n\n\n

Set\nscrews: Two 50mm 5mm\u00d8 set screws (leg pivots) plus 5x30mm fender washers 4;\n5mm flat washers 4; 50mm CSK *(countersunk head) 5mm\u00d8 set screws 6 to\nsecure hinges to table frame; 2 5mm\u00d8 Nyloc nuts to secure leg pivot bolts<\/p>\n\n\n\n

40mm\npanel pins to secure tray and table corners 3 panel pins per corner<\/p>\n\n\n\n

40mm\nwood screws to secure the cross brace to the pair of legs at the front\n(opposite side to where the user would be sitting; there is no brace on the\nuser side, where a careless foot might hook it)<\/p>\n\n\n\n

Two\nhandles of your choice for the tray<\/p>\n\n\n\n

Meranti\nwood filler<\/p>\n\n\n\n

Wood\nglue<\/p>\n\n\n\n

Finishes:\none can appliance spray (white) to seal the table top; clear varnish for the\ntray and table frames, legs and crossbeam<\/p>\n\n\n\n

*Optional<\/p>\n\n\n\n

Method:<\/strong><\/p>\n\n\n\n

You\ncan make the tray first, and then the table in which the tray sits, or you can\nmake the table first, and then the tray, sizing it to fit on to the table. We\ndecided to make the tray first\u2026<\/p>\n\n\n\n

Note that the cutting lists given above are approximate. You need to dry fit and then cut to size all pieces, the dimensions of which will, naturally, depend on how big you maker your tray and table ensemble. The tray and table featured here has a working height of 620mm an ideal height to suit being placed in front of a sofa or easy chair.<\/p>\n\n\n\n

    \n\n\n\n
  1. The first step is to mark off your Perspex sheet. If you decide not to use the Perspex then ignore steps 1 thru 4.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  2. The first step is to mark off your Perspex sheet. If you decide not to use the Perspex then ignore steps 1 thru 4.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  3. See this is what can happen!<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  4. You need to deeply score it on both surfaces and then gently snap it; if you have scored it deeply enough on both surfaces, you will achieve a clean break. If not\u2026 this is what happens. Note that the protective film has not been removed from the sheet yet. Leave it on to the very end.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  5. Apply 2 or more coats of white appliance spray paint or the paint of your choice using a roller and allow it to dry, and then cut the tray base to precisely the same size as the Perspex, using the latter as your template.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  6. You had your 12x96mm meranti ripped at your local Mica. Now cut the 2 sides and 2 ends for the frame; note that these joins are straight, so you need to allow an extra 24-25mm for the sides so that the ends of the ends are completely covered.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  7. This is how the corners are joined using glue to secure each corner.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  8. I reinforced the corners with 3 x 40mm panel pins each note how the middle one is at 90\u00b0 but the two on either side are angled inwards. This is deliberate: it stops the corner pulling apart.<\/li>\n\n\n\n
    \"\"<\/figure>\n\n\n\n
  9. This is the cross section of the bevel beading 10x19mm used to secure the Perspex and hardboard below\u2026 both are sandwiched between the beading on top, and beading glued below.\n\n\n\n
    \"\"<\/figure>\n\n\n\n