Make XXL Extensions to Create a Large Square Dining Table

The goal ? Being able to transform a 220x85 cm (86x33 inches) table into a giant square table measuring 220 x 220 cm (86x86 inches) ! But without adding feet that could bother the guests’ legs!

The current table is solid oak with a central leg, it is very heavy and will provide a good base for the project.

The idea: create 2 extensions on the long sides of the table, removable extensions, and hollow to limit the weight (slat structure and 10mm CP in sandwich).

These extensions are placed on steel tubes, themselves inserted into a larger tube, fixed under the table.

Supplies

Material used:(some links paid by Amazon)

As my translation is surely approximate, I will provide you with links to a French store so that you can see better for yourself with photos.

Step 1: Video

Because it's clearer to see how to do it, here are all the steps in video.

Step 2: Plans

For the plans, I started by modeling the project with Fusion 360, then I produced side plans.

PDF plan attached.

Rallonges table plan MagicManu.pdf
Download

Step 3: Structure

The goal being to make lightweight extensions that are easy to transport, there is no question of using solid wood.

These extensions are therefore hollow, made up of a batten structure, surrounded by 2 plywood panels.

So I used fir battens with a section of 27x47mm. They are cut 4 by 4 with a miter saw, then assembled with 4.5x60mm screws.

I didn't make a pilot hole because I used an impact driver.

Step 4: Sandwich Boards

For the boards I used 10mm thick plywood. I had them cut to the right dimensions by my DIY store.

I created handles by making 2 holes of 40mm in diameter with a hole saw, then I finished with a jigsaw.

I then fixed these panels, on the structure, with screws, then nails (using a pneumatic nailer)

Step 5: Finishes

I leveled the edges with a cutter equipped with a ball bearing to rectify the boards that were sticking out.

I then rounded all the edges with a quarter round cutter mounted on a trimmer.

And finally I finished by sanding the whole thing.

Step 6: Support Tubes

The extensions will be placed on 30x30 mm hollow steel tubes, I cut them with a metal miter saw.

To fix them, I drilled a 30x4mm flat iron with a drill press, then cut out sections to make fixing brackets. They are welded on each tube.

Once the tubes were thoroughly cleaned with acetone, I painted them ironwork black.

Step 7: Blocking System

To create the blocking system, I am not very equipped to work with metal, so I used pieces of square tubes, which I opened on one side to create the necessary shape.

I added heat shrink tubing to make it prettier and secure better.

A system of knurled screws and nuts allows the tubes to be easily dismantled and reassembled.

PDF plan attached.

Supports Rallonges table plan MagicManu.pdf
Download

Step 8: Fixings

These blocking systems are fixed under the boards with threaded nuts.

Step 9: Ready

Everything is ready ! The set is made up of 2 extensions, 2 tube supports (which will be fixed under the table), 2 tubes, and 4 locking systems.

Step 10: Mounting on the Table

I marked the location of the supports, I made a pilot hole, then I fixed them with 6x60mm lag screws.

I took the table top apart and turned it over to make it easier to work with.

For assembly, simply slide the 30x30mm, 2 meter long steel tubes into the supports, place the extensions on top, then block them with the locking systems.

It is very solid, you can lean on it without problems, the table is not likely to tip over.

I also cut 2 tubes shorter, allowing us to only use one extension if we don't need both.