I wanted to make a desk that was able to be disassembled and packed flat, made from few and easily obtainable supplies with simple tools.
The desk can be created from the following supplies:
1 4'x8'x3/4" A-1 plywood sheet
2 4' 3/8" steel rod
2 3/8" nuts
2 3/8" wingnuts
You will need the following tools:
Circular saw (or other saw for making large cuts in the plywood)
Coping saw (for cutting the notches)
I also recommend a squaring device such as a speed square.
Step 1: Create the tops and the sides
Two of these will be for the top and bottom of the desk and two will be for the sides. I recommend using the smoothest and most regular surface for the top of the desk.
Step 2: Cut notches into the sides of the top and bottom pieces
Step 3: Cut the tabs in the legs
Step 4: Cut the sandwich spacers from the legs
You could do this step earlier, but I waited until after I was done cutting the notches and tabs just in case I made a mistake and had to change things.
At this point you should also cut your desk to the height you want it to be. Since you're making it yourself you can customize it to your chair and your liking. Just make sure you cut the legs to the same height.
Step 5: Sandwich the top and bottom together
Step 6: File and sand the notches and tabs to make a tight fit
Filing is a major pain. Not only is it labor intensive and time consuming, it can damage the veneer. If I was doing this again I would have spent more time or gotten another tool to do the cuts to make them more accurate. More accuracy on the cuts would have make the filing portion a piece of cake.
Step 7: Drill holes and install the steel rods
The rod I used was 3/8" in diameter.
Step 8: Sand, finish, and install
When your finish is dry insert the legs into the sandwich and insert the rods into the legs. Use nuts and washers on the insides of the legs and a washer and wingnut on the outside to tighten and secure the legs.
Originally I wanted to have two 48" threaded rods as the extra support. I couldn't find any at my hardware store so i had to get four 24" ones and two couplers. This turned out to be great because it made it much easier to put the piece together.
Step 9: Marvel at your greatness
Thanks for checking out the Instructable. Please let me know if you have any questions.