- Made at Techshop (www.techshop.com)
Step 1: Buy Materials
4 leg pieces - I used 2"x2" square profile steel tubing, 1/8" thick, 28" long (after final cut)
4 square table mounting pieces - 6"x6" x 1/4" thick steel, wit 4 holes drilled near corners to attach final welded legs to wood table underside
4 metal bases - One large 12" x 40" x 1/4" thick steel piece which was plasma cut to make 4 bases for the 4 legs
Metal cost: ~$60-80 depending on where you go to get the metal and if you can use some scrap/salvage metal
1 solid core wood door - cut down to specific size, 32" x 60" birch, 1 3/8" thick
Wood cost: ~$80
Wood stain + polyurethane varnish (or spray cans) - I used matte for wood, gloss for metal legs to increase shine
Wood mounting screws
Felt sticky pads to put under table legs and prevent floor scratches (+ allow easy movement)
Supply cost: ~$40
Total work desk cost: ~$200
Comparable furniture design store cost: $1500-$3000
Step 2: Cut Metal Bases to Length
Step 3: Polish Legs
Step 4: Plasma Cut Metal Bases
Step 5: Cut/machine Metal Top Squares
Step 6: Clean Metal Components
Step 7: Weld Metal Bases Together
For aluminum bases/legs TIG welding can be used (not done here).
Step 8: Polish Metal Bases
As the legs are now done and ready, you can spray coat with sealant to prevent rusting. I used a standard marine clear coat coat spray, gloss finish, 2 coats (let the first coat dry before applying second coat).
Step 9: Buy Wood Desk Top
Step 10: Stain and Weather Coat Wood Desk Top
Using a wide, good quality brush lay down a coat of wood stain with the table top lying flat on the ground. Wait 5-15 minutes for penetration (longer will make it stain darker), then using a cloth wipe off excess stain.
Coat and wipe off stain application in direction of wood grain, using even strokes. When removing excess you can even out coloring by applying some pressure onto the wood.
Let dry for 4-6 hours and coat underside of table top.
A second coat can be applied for darker stain.
Wait a day then spray coat or brush with polyurethane sealant. This will prevent water damage if you spill on the table. 2-3 coats can be applied. I prefer matte finish for the wood.
Step 11: Add Mounting Screws Into Desk Top
The best way to find the location of these screws is to place the desk top on top of the legs in the position they would be used (2 people make this easier) then ark with ink or do a small pilot drill from the bottom. Measuring exact dimensions can be tricky so I prefer the 'pre-assemble' method.
Step 12: Assemble!
Add felt coasters on the bottom of each leg to prevent wood floor scratches and allow easy movement of the desk.
Ready to use at a fraction of the cost from a designer furniture store and stronger than an IKEA desk for sure!