Picture of Stylish Coffee Cup Trays
Make some small stylish trays, to serve coffee (or tee).

I use Plexiglas (remaining from a former project). You could use real glass too, but it would require more skills and tools. Plexiglas is very easy to cut, but will get scratches, eventually.
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Step 1: Needed Stuff

Picture of Needed Stuff
  • 2 mm thick Plexiglas (acrylic glass)
  • Hard wood strips (I used beech) of rectangular profiles
  • Hard wood strip of round profile
  • Cutting mat, metal ruler, cutter
  • Wood, paper, and epoxy glues
  • Wood primer
  • Masking tape
  • Clamps (optional)
  • Jigsaw
  • Sanding machine (or just sand paper)
  • Drill (at best: drill press)

Step 2: Sketch Some Designs

Picture of Sketch Some Designs

Step 3: Make the Long Sides

Picture of Make the Long Sides
  1. Cut the paper sides,
  2. glue them on the wood,
  3. saw them carefully,
  4. drill (beware: not through) [*]
  5. with a short piece of rounded profile, put the sides together (without gluing them),
  6. sand them for perfect alignment,
  7. soak them very shortly in water, to remove the paper.
[*] precision is important here: it will insure that the Plexiglas will fit well and not slide away.

Step 4: Make the Board

Picture of Make the Board
With the cutter, strongly mark (two firm passes should suffice) the Plexiglas on both sides.

Hold the Plexiglas between two boards (or in a large vise) and snap it firmly, to break it along the mark.

Repeat to obtain desired size.

Sand the edges. Check that long edges are very parallel.

Check size against wooden sides.

Step 5: Assemble

Picture of Assemble
Cut rounded some rounded profile to length (board width plus some extra millimeters).

Glue them to the sides (dip the ends into some wood glue).

Let the glue dry.

Step 6: Make the Short Sides

Picture of Make the Short Sides
Cut the short sides to length. They must be approx 0.1 mm longer than the Plexiglas width, so that the Plexiglas can slightly slide.

Glue them with epoxy, use masking tape to keep the right position.

Let the epoxy cure.

Advice: from now on, always remember which Plexiglas board belongs to which frame.

Step 7: Sand

Remove the Plexiglas.

Sand the wooden frame (optionally, with a power sander).

Step 8: Prime Time

Picture of Prime Time
Apply wood primer, and let dry.

Slightly sand to get a smooth surface again.

Step 9: Clean and Place the Board

Picture of Clean and Place the Board
Remove the protective sheet of the Plexiglas boards.

Clean the Plexiglas with water.

Place each Plexiglas into the frame it belongs to.
punkhead583 years ago
Very elegant design. If you don't mind me asking, what are those round brown things next to the coffee cup in the first picture; perhaps cookies of some sort?
bertus52x114 years ago
Very nice!
Just one question about step 4. Did you cut the plexiglass with a Stanley knife and then broke the rest?
How deep did you have to cut?
laxap (author)  bertus52x114 years ago
Yes exactly. Somehow the text of step 4 got lost, but thanks to the history feature I could restore it.
Ok, thanks but how deep must you cut with the knife (half way?).
laxap (author)  bertus52x114 years ago
The cut is here to just mark where the plexi should break.

I just measured... Approx 0.2 mm deep, on each side; it's OK for a 2.4 mm thick plexi.
ok, thanks!
Lorax984 years ago
Thanks for the pdf. I have students that will want to build a few of these in shop class. These will make great gifts.
laxap (author)  Lorax984 years ago
You're welcome.

I'm, glad to hear it's being inspirational. Don't hesitate to make your own designs (so you'd need the ODG format). Keep in mind that my attached docs are in metric units (A4 sheet, grid in cm).

Please post some results!
joshfromga4 years ago
very nice! though when i saw the thumbnail i thought it had a mini zen garden under the plexiglas. still a great gift idea.
laxap (author)  joshfromga4 years ago
adding a mini Zen garden, what a great idea it would be!
Lorax984 years ago
Please print your sketches to pdf and repost the files.
laxap (author)  Lorax984 years ago
Biggsy4 years ago
These are beautiful... Great pictures too... Well done and awesome I'ble!
Dr. Pepper4 years ago
amazing, love it! great job!
ijibang4 years ago
It's a piece of ART .... real beauty ... thank you for sharing!
Yeah, real wonderful!
laxap (author)  andreaboylee4 years ago
These are really nice! Good instructions, too. Thanks.
laxap (author)  stringstretcher4 years ago
Thank you!