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Now that football has started, it's harder to find time in the shop to finish the table. This weekend I eeked out a few hours to get started on the circular pedestal that will raise the Egg to the proper height. I cut 16 pieces of cypress and mitred each end to 11.25 degrees.
In order to make this round on the table saw I need a point in the exact center. So I glued a brace right in the middle. This brace will serve two additional functions - a way to attach the pedestal to the bottom shelf with no visible screws and as a support for the weight of the paver and the Egg.
I went over to my woodworking board and asked for advice about orientation of the staves. The consensus was that joining on the end grain was the lesser of two evils. The joint would be weak but the expansion/contraction of the wood would not be such that it would tend to tear the joints apart. I just used Titebond III, but I put a lot on each joint. The end grain was sucking it up as fast as I could spread it on.
This thread's amazing. Thanks for keeping us updated.
Progress has been really slow for several reasons. First, it's football season and I have spent the last 5 weekends in a row traveling to college football games. Second, I hate the "finishing" phase of a project. And third, I've been grilling on my BGE most weekends rather than spending time in the shop! One thing you learn when grilling is you really need some work surface around the Egg and some storage.
So this is all I have in the way of progress to show - a photo of what the spar varnish finish does to the bare cypress. I expected this, which is why I chose not to stain the cypress. I knew the varish would give it a nice yellow hue. I am finishing before final assembly because it allows me to keep the surfaces horizontal and reduce the sags and runs I might get if had to apply the varnish on a vertical surface.
Why the small wheels? I put 5 inch wheels on mine and they are smooth as glass. I never had good luck with the smaller wheels for outdoor applications.
I selected the casters based on the size of the mounting plate, the ability to lock, and the load bearing capacity. Anything larger and the plates would have been bigger than the table legs. I don't anticipate moving the table all that much anyway. It will only be moved around when I need to re-seal the deck each year (or two).
Thanks for the question. One of the reasons I started this thread was to generate discussions about design options, materials, and building techniques.