How to Make a Modular Outdoor Table

hey I'm Bob at I Like To Make Stufftoday I'm gonna make a table that looks like this or this or this here in ourbackyard we've got an old gazebo and it's a really great place to sit andhang out it also it would be really nice to be able to have a meal out here sowe're gonna build a table to put right in the middle we've got six people inour family and the gazebo is a hexagon so we decided to mirror that shape andmake a table that had a space for every person we laid it out here on the woodon the floor to figure out the overall size basically just making sure thateach section was large enough to pull a chair up too and there was enough roombehind it to walk around the table but rather than one giant table actuallysplit this down the middle and we're gonna make two tables instead I did thatso that we can split it up and use it in different places both in here and out inthe yard I measured the longest point of this hexagon and made sure that it wouldfit against this railing so if we want to have a large opening in the middle wecan split it up and put it against the sides we've got our measurements we'vegot our shape let's go make it to cut down all the steel I'm using a new tooland this is a large band saw for cutting metal this is one of the cheapest ones Icould find and it wasn't very expensive so you could totally pick one of theseup if you're going to be doing a lot of metal fabrication of course like I'vesaid before there's a bunch of different tools you can use to cut down steel wedid a whole video recently on angle grinders and that's still a great way tomake pretty precise cuts on all sorts of tubular steel so in this case we'regonna start with the square tubing because all the cuts need to be at 90degrees so we're gonna put them in here and cut all the legs first when you put the two tables togetherthey're gonna make a hexagon so 360 degrees divided by six sides makes eachone of the angles and all the corners 60 degrees so we're gonna have to cut someangled cuts on all these pieces that need to be pretty precise we're gonnause this bandsaw again for that currently it's cutting at a 90 degreeangle so it cuts straight cuts which is simple but this saw also is made to beable to rotate this piece and hold the workpiece at a different angle so we'regonna set that up and start making some angle cuts it's kind of weird cuz I had to flip itaround and over and since this is an angle iron it it's not sitting on a flatside luckily this little vise holds it in place and I think it's gonna hold itat the right angle so this thing can cut through it but we'll find out alright sothis is the first single side I've got the right angles on there so this one'sall good to go and now I just have to make quite a few more I've got all that steel cut down now andthat saw was really helpful it made it a lot even but also a lot more precise andin this case with the angles needing to match and be exactly correct that was abig plus alright now it's time to put this thing together let's lay it on thefloor and start welding now the only pieces that haven't been fully cut arethis back piece right here this actually needs to sit like this and these outercorners needs to wedge together so I'm gonna lay this in place and then Markoff the section to cut out of this bottom panel so that these can kind offit together but before I cut those corners out to fit them together I wantto make sure that these three pieces are in the right position so I've got themlaid out relative to that long side and now I'm gonna just tack these togetherand we'll go back and cut those out when you're putting pieces into theangle iron you got to remember that there's a small radius on the inside ofit so you got to knock off the corner of the piece that's going to sit in thereso that it will sit all the way in now I've got these in place it's time totack them and then go full weld everything one thing I want to note here is that Iam welding on concrete and generally that's a bad idea because if you put toomuch heat in one spot right up against the concrete the concrete can explodenow in this case I'm not spending too much time in one area so I think I'msafe but just be aware of that don't do a whole lot of welding in one littlespot when it's sitting on concrete alright so now it's time to finish outall these welds so montage time I've got all the full welds in but likethese need to be completely ground flat because a leg is gonna sit right here soI'm going to grind this one down and then this one down on the outside sothat you don't see the well and to do that I've got a couple of grinders setup one with the big fat grinding wheel and then also a sanding disc so that Ican really smooth out the final finish this video is sponsored by audible whichis a great service for getting audiobooks if you want to get a freetitle and – audible originals plus a 30-day free trial go to audible.

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com/makestuff I've got all the big welds off but thesurface is still pretty rough so we're gonna switch over to a flat disk and wedid a whole video on angle grinders and all the different things you can usethem for go check that video out if you want to find out why you would use onething over another the frame is pretty much done now I justgot to put on the legs and I've got these big square tubes to put on thesehave already been cut flat like you saw earlier so we're gonna set these righton this face now I intentionally got the same size for this and the angle iron soit should line up pretty well I just have to decide exactly where I want tofit the pieces since you're gonna be able to sit at every side of this tablethese are square so they can't really fit into the angles so at some pointyou're gonna see the side of a leg versus the front of the leg it's not abig deal just gotta make it uniform all the way around and this is going to be awelded butt joint this edge right against this edge so when I go back anddo is chamfer this so that there's a little recess and it will be able tofill up with the filler material when I weld it I'm gonna use this magnet to hold thisin place and that should also make sure that it's at a 90 degree angle to thissurface so once I've got that there I'm justgonna tack it run around and tack all four of these in place and then go backand do the full welds as usual and I should say that the reason that you tackthese before you do the full welds is as you add a lot of heat to a joint itstarts to warp the metal a little bit so if you tack them in place first it keepsthem where you want them and it's not going to warp and make the the legs leanas you add the full welds the last little bit of welding we got to do is toput in a couple of support so now these are gonna go in here just need to betrimmed down and those are gonna support the wood that's gonna lay this way it'sa really long span and it'll end up flexing if there's nothing underneath itit also acts as a spacer this is a half inch piece the material that's gonna beon top of this the wood is gonna be three-quarters of an inch and that fillsup this gap on the inside of the angle iron so theoretically the wood should beright at the top with the same level as this outside edge that wraps up all the welding so thelast thing is to smooth out these welds on the faces where the legs attach tothe frame I'm not going to touch the welds on the inside because I want themto stay there and stay strong but I want the aesthetic of a smooth transitionbetween the leg and the frame all right so finished up the first framenow I just have to make a second one now one of these actually turned out reallywell the legs are straight down the other one works just fine and by itselfit looks fine but when you put them next to each other you see that one of thesesets of legs is flared out a little bit it's possible that I put too much heatand everything bowed I'm not really sure what happened but the good thing is thatall of the legs do sit on the ground it doesn't Rock it doesn't wobble there'sjust a little bit of gab done here not too long ago I made a lounge chair to goin the backyard I'm gonna mimic that look a little bit with these tables sofor the tabletops I'm gonna use strips of cedar now first off I have to cut apiece to go right here that's gonna act as the anchor on both ends of each oneof these side tables then I have to rip down some slats to go all the way acrossI measured this full width divided it by five and that's gonna tell me how wideeach one of those needs to be so I've got this big stack of cedar boards I'mgonna take these over to the table saw and rip them down to the right width I put some spacers across the table andthose are half-inch thick now these boards that are gonna act as the spacerson the ends or 3/4 so I'm going to run them through the planer to get them downto the same thickness in an ideal world these angles would all be exactly theright but I know myself well enough to know that they are probably not perfectso instead of pre cutting all of the angles on the pieces of wood I'm gonnalay them out across here and get all the gaps in between the pieces the same thenfrom there I'm gonna strike a line from this corner to this corner across thosepieces and that tells me the line that I need to cut and then also make sure thateach one of the pieces is exactly cut to fit within this side and within thisside and there's a good chance that the ones that fit on this table will notnecessarily fit on that table so we're gonna take it one at a time cut eachpiece so those first cuts were actually justkind of approximate just to be able to fit the pieces down inside the framethey're not exact they're not all at the same angle and currently they make theboard's just a little bit too long so I'm gonna have to go back and trim eachone just a little bit to get them in there then we'll fix them together thenwe'll take the whole thing out and cut a nice clean edge on both of these angledsides I got that piece trimmed down and that let me get the space in betweeneach one of these even so now they're laying in place on top of the woodenspacers that I put in here on the edges so I'm going to drive some Brad's upthrough those to hold all the wood together and then we can take the wholething out trim the clean edge and then put it together with some screws so thatit'll be nice and strong you can see here that this edge is not the samedistance from the steel on all these different boards and the angles are notall the same so now we're gonna strike a line about an eighth of an inch in fromboth corners all the way across that'll give us a reference line to cutall of them and so the gap will be the same all the way down so now I've got this whole gap down hereis the same all the way across it looks good all the way around so the lastthing is to finally fix these top pieces to that under support we're gonna flipthis over and use some stainless steel screws so the last outside I alsodrilled holes and all the steel so I could drive up some stainless steelscrews from the underside into the bottom of the table I use a chamferingbit on a router to soften the edge where your arms would go all the way aroundthe table then we gave the tabletops a really good sanding made sure to get ridof all the extra dust to get it ready for finish outside I spray-painted bothof the frames with an enamel paint enamel hardens and is really good foruse on metal surfaces and for things that are outside we did a whole bitsvideo a while back on why you would use different finishes different varnishesto cover surfaces for this one you're gonna use a spar urethane because it'sgonna be outside it's gonna protect the top surface and it should be pretty easyto put on and after this dries is just a matter of screwing this onto the framesand we're all done so the pieces together work as one bighexagonal table it's plenty of room for chairs to pull underneath it and you gota lot of elbow room next to the person next to you in fact you could probablyput a short bench here and put two kids and each one of these sides so you couldhold a lot of people but you can use these two tables in a differentconfiguration here too another option is to push the long side of each of thesetables up against the outside rail they fit in each one of these segments so youcan put them together to make this shape you could put them across from eachother but you can take them out of the gazebo and actually you do somethingelse with them if you put the tables in to end you end up with a big long tablewhich is really cool and just proves how versatile this shape is of course it'sreally simple geometry but it does prove that middle school math was worthwhile Iwas really happy with how these things turned out I'd love to know what youthink about them so let me know down in the comments I've also got a whole bunchof other types of videos that you may be interested in check some of those outdon't forget to subscribe and hit the bell so you get notified as soon as Iupload that's it for this week guys thanks for watching I'll see you nexttime and snap guess I shouldn't say snap heyI'm Bob it I like to make stuff today I'm gonna make it tape so we've got ourshape from this now let's go make some steel make some steel make some goforward steel.

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