The HANG .10 coffee table is a think-outside-the-box expansion from the Eames/Herman Miller surfboard table's original design.
The name comes from the 2 racing stripes made of Canadian dimes and the option to hang it on the wall if you so choose.....hence the name HANG .10 Since the name is also a surfing term - it would only makes sense to shape it like a surfboard too :~)
The dimes were laid with 1 stripe having all 'heads' showing while the other stripe was showing the 'schooner'.
There is 2 keyhole slots routed in the back. This allows it to be hung on the wall if you get tired of it as a table.
I tried free online drawing software to make the ellipse to the size I was after. Once I had the correct size, I could just print out the 'tiles'. Since the printer cannot print out something this big as one sheet - it will break it down into smaller pieces called 'tiles'. Once the tiles were printed out - it was simple enough to lay them out and tape them together.
Once it was all taped together and laid out on the floor, I then cut out the elliptical surfboard shape. This is what gets used to make the wood template.
It took about 2 days to get to this stage because I never used this software before. Next time, I will use the 3 nails and string method to get my ellipse.
We need to make a jig:
Take your paper template and trace its shape onto the wood that you will use for your jig. I used 1/2" MDF but you can use 1/4" MDF, Masonite or plywood.
Use your jigsaw now to cut out that shape from the MDF. Once cut out, I took a belt sander and cleaned up and smoothed all the edges around the jig. This will be your main jig now. This jig is what the router bit follows to cut out your perfect ellipse.
Select your wood to make your table from. I chose pre-finished birch.
Now put the wood template onto the wood you're selected and clamp it down.
Proceed to route around the jig with the router bit riding against the jig. I used a 1" pattern bit with a ball bearing. This is what rides against the edges that I smoothed out earlier on the jig.
Once the main shape was routed out, I switched to a 22.5 degree router bit and routed around the edges once again. This gives me the 22.5 degree bevel on the edges just like the Eames table has.
Now you're done this step and your table top is ready for your design.
I masked off the edges and painted only the top black. I left the edges to show the different plywood layers similar to the Eames table.
I laid out the location of the stripes with painters tape.
Now you can throw down some dimes!
I used white glue and Q-Tips. Type of glue doesn't really matter because the whole table will be getting covered with epoxy resin later.
I removed the painters tape and now I can lay out my chrome maple leaf decals.
I originally tried to cut them out myself with a x-acto knife - but it wasn't very neat and I wasn't sure I would make this deadline! So, I called Rich at Platinum Autosports here in Kamloops, BC. He was able to cut out 50 chrome maple leaf decals for me on the computerized cutter.
I then laid out all the decals into the pattern I wanted.
Ok, now its time for the epoxy resin coating. You will need enough for a minimum of 2 coats.
I mixed my epoxy in a 1:1 ratio. This maybe different with other brands though.
I poured the epoxy, and waited 10 minutes for all the bubbles to come to the surface. Now you can take your plumbers torch and wave it around the surface of the table popping all the bubbles. Keep the torch moving at all times and about 6" away from the surface to avoid burning the epoxy.
I waited overnight and did a second pour of the epoxy.
You have to try your best to avoid airborne dust and grit from getting onto the top.
You should wait about 4 days for the epoxy to cure. Then you can move it around and finish it off.
I attached these nice 13" powder coated hairpin legs. These seem to be really popular right now.
I used a keyhole router bit and routed out 2 keyhole slots. This will allow me to hang the table on the wall if I tire of this as a coffee table or if I want to use it as art. They are spaced 16" on center to allow hanging onto the wood studs.
And finally to finish it off....a customized nameplate using a military dog tag. I think that finishes it of nicely :~)
And here's the final product.....
Hope you enjoyed this Instructable and good luck.
HANG .10 everyone....