If you're interested in more of what my class has done, visit our blog www.theresponsiblestudio.tumblr.com !
Step 1: Materials
.1/2"x6" double threaded galvanized steel pipe nipple (you will need 2)
.1/2" galvanized steel 90 degree elbow (you will need 2)
.1/2" galvanized steel floor flange (you will need 2)
.1"x30" PVC pipe (you will cut this in half)
.1" PVC coupling (you will cut this in half)
.1" PVC end cap (you will need 2)
.42"x22" of catch-tray material
.thread and sewing machine
.glue/thread lock (optional)
Step 2: Step 1: Prepare Materials
-Cut the double threaded 30" steel pipe into two equal 15" lengths and sand the edges.
-Cut the 1" PVC coupling in half and sand the edges.
-Cut the 30" length of PVC pipe into equal 15" lengths and sand the edges.
Step 3: Step 2: Mount Hardware
**For our catch-trays we mounted the floor flanges onto a piece of 2X4 wood first and then mounted that piece of wood onto the underside of the table. If you're worried about keeping the flanges perfectly even or have trouble accessing the underside of your table this might be a good solution for you as well.
Step 4: Step 3: Attach Steel Pipes
Screw the 90 degree steel elbows onto each 6" steel pipe. Make sure that these are screwed in as tightly as possible while still pointing out towards the bench-pin.
Screw the 15" lengths of steel pipe onto the elbows as tightly as possible.
**For our studio, we used thread lock to secure these threaded joints. This will probably not be necessary for you, but if your catch-tray will be used by many people or you think it may experience a lot of wear and tear, glue may be helpful.
Step 5: Step 4: Getting Started on the Tray
** For our catch-trays, we were given tarp-like material that is typically used for heavy-duty banners. If you don't have access to this kind of material, anything that is easily washed out and won't wear out will work. Some suggestions we had are tarp, leather, pleather, and vinyl. Get creative!
Step 6: Step 5: Sewing!!
First fold over the edges on the left and right sides to meet the solid line so that the Sew along the dotted lines. It is a good idea to pin these seams first and check to make sure the pvc pipe will fit into the channel. Also be sure to reinforces the beginning and end of the seam so that it doesn't unravel over time.
Once both seams are done you can move on to the the darts. Before you sew the darts, make sure you pin them so you can be sure the material doesn't bunch or pull. You want a nice rounded tray without corners or folds that may trap dust and scraps Overlap the edges of the darts to form a "V" until the pieces create a straight line along the back of the tray. Sew along both edges. Repeat this for each dart.
Step 7: Step 6: Assembly
Insert the 15" PVC pipes into the channels in the tray. Attach the 1/2" PVC pieces onto the back end of the PVC pipes. Attach the PVC endcaps onto the front ends of the PVC pipes. Make sure that they are secured. We used a hammer to gently tap them onto the PVC pipe.
Step 8: Step 7: Start Catchin'!