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2011-09-27

Making the go-bar deck

In order to glue the struts, I need to make the go-bar deck.
I was thinking to attach the top deck to the solera, which I will be making using 2 pieces of 1cm thick plywood.
This probably won't be strong enough and so I added a cross-bracing to the top.
I started making the notches in the bracing and it's a good way to improved my chiseling skill.
Now I am pretty confident of making a normal dado or mortise-tenon by chisel.
Not perfect fit but acceptable.
I realised the crucial part is that the chisel must be real sharp.
The rest is just getting them to fit.

Gluing 2 pieces of plywood together

Sawing the edges straight. After that I followed up by chiseling and planing to make the 2 pieces flushed.

Chiseling the notch

Cleaning the notch to make them fit.

Notch done

Gluing the x-brace down.
The middle part I use another scrap to press down.
I don't have any clamp that is that long reach.

X-brace done. The X-brace will help to keep the plywood flat too.

After that I drilled the holes for the top and bottom board.
I've decided not to attached the top board to the solera.
This makes it easier for me to use the deck for back struts too.
Due to the position of the X-brace I could not drill exactly at the corners but I have to drilled to fit the 2 boards.

I assembled the board with 3 legs, for the last leg the hole had some chipped pieces
I glued them back.
With just 3 legs, the assembly is kind of wobbly...
I wonder would it be able to withstand the pressure of the go-bars?
The last time I use the Aluminium go-bars on the table the entire table rose up...
I had put books and other heavy weight to weigh it down.
Well if the threaded rod doesn't work then I have to build using wood legs.

Drilling the hole 10mm to allow the threaded rods to go thru'

Assembly.

The parts

Go-bar deck assembled

Another view

Another view

Testing the deck. Test run of the gluing process and adjusting the height of the deck to exert enough pressure and the go-bars are not too curved.

Close up of the doming of the struts

I have made some more go-bars for the gluing.
4 for each struts 7x4 = 28 and 2 extra.
That should be enough to start the gluing process.

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