|Tea tray in sycamore and scots pine.|
Most of the work for me was in milling the lumber on hand into thicknesses equal to what Charles Hayward used. I resawed some laminated pine I had for the main panel from 18mm down to 1/2". I also had some sycamore two inch posts that I cut down to 5/8" widths.
I did run in to a few problems with this build. Just in case you would like to build one, perhaps this info will help you.
First up, I re-did the cut list because there was an error in quantities. It was also listed in feet and inches. Iprefer than just inches.
|Edited cut list in inches and millimeters.|
I chose to repair this goof rather than cut it off and make the tray a little shorter. I wanted to see if it could be repaired with a decent looking patch. I think next time I do this I'll do a better job, but it looks good enough for now.
After that was a giant goof-up on my part. There aren't many pictures in the article, and I was mistaken in what I thought it said to glue up. For some reason, I didn't even question it in my head. I glued the base to the upper part rather than screw it from below, as stated in the instructions.
|Don't do this.|
The problem with gluing the base is you are locking the panel in the base to a specific width, without allowing for the fact that the panel will expand and contract over time. I have no doubt that it won't take too long before I get this tray back with a cracked base or some other catastrophic failure. When that happens, I'll fix it by doing it the correct way: no glue, screwed from the bottom with the clearance holes in the base a little oblong so the wood can move past the screws.
I might have even just nailed the bottom on if I had been thinking.
I might get lucky, because pine can be a pretty stable wood once it has fully cured. Time will tell.
Last, I had a difficult time understanding what I was looking at in this picture:
|It looks like the handle rests on top of the tab.|
I came up with making these parts in 1/8" sycamore:
|This is one piece of wood, not the support with the handle on top of it, like I thought.|
|Looking at it from the side, this is the shape of the piece I made.|
|This is the shape the piece should be.|
|The dotted line represents the rabbet.|
Once I figured out my way wasn't going to hold, I had to come up with a way to fix it. I decided to use bamboo skewers as dowels to reinforce the joint at a 45 degree angle.
|I kind of like the look of this joint.|
In the end, I decided all the faults of this tray did not detract from it enough to prevent giving it to the intended recipient. She was thrilled, and thought it looked very nice.
I just told her if the base starts to rock or if it cracks, to bring it back and I'll fix it.
At least I used hide glue, which is reversible.