Here is the plan for the Serving Tray:

Link to the PDF version: https://docs.google.com/fileview?id=0ByU67OqW1u9vNTQwZWY4ZTMtYTg0OC00OGJlLThmYWItMDgyZTQwNzI2YzVh&hl=en



Cut List:
A – Qty=1-(bottom of tray from 1 x 12 board): 11.5” x 21” x .75”
B – Qty=2-(sides of tray from 1 x 4 board): 27” x 3.5” x .75”
C – Qty=2-(ends of tray from 1 x 2 board): 11.5” x 1.5” x .75”
D – Qty=2-(dowels for handles): .75” dowels cut to 13” length


Template for handles:

Directions:

1. Transfer handle pattern to ends of side boards (B)

2. Drill .75” holes in ends of side boards (B) per the pattern – tip: put a piece of scrap wood under the board that you are drilling to minimize “tear out” to the other side of the hole you are drilling.

3. Cut side board (B) to shape by using a jig saw

4. Thoroughly sand the board to smooth the edges that were cut in step 3

5. Attach end boards (C) to bottom of tray (A) using glue and 1.25” nails make sure edges are flush.

6. Glue dowels (D) into holes in side boards (B) and quickly glue and nail to the bottom (A) using 1.25” nails – tip: you should dry fit this together to make sure all is going to fit well before you apply glue. You want to attach dowels first, then attach to the bottom, but don’t let the glue set on the dowels so that you can make sure everything is squared up and flat before you nail to the bottom.

7. Remove excess glue before it hardens – it sometimes helps to let the glue set for 15-20 minutes so you can remove it while it is still a bit rubbery.

8. Sand, sand, sand to remove saw marks, soften edges and remove glue I usually start with 100 grit, then 200 grit, then 800 grit – to get that “soft as a baby’s behind” finish.

9. Add stain or paint







Link to inspiration piece: http://www.touchofclass.com/product/r912-001.do?code=CMS06