End Table Project ePlanSet

M
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AKING

FURNITURE

from Plastic Pipe and Pipe Fit- tings is quite a bit different than doing a Plastic plumbing project. You dont have to worry about the slope of your drain line, and you dont need to bother to check for leaks, once the project is fully assembled.
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However, you do need to be very accurate when you cut your pipe to the various lengths required. You do need to make your cuts square. When you assemble the pieces, you must make sure each pipe is fully seated into its fitting. If you dont fully seat each joint, your effective, or assembled length will not be right. On a project like this, if your assembled lengths vary, you will not be satisfied with your finished project. Building this End Table is a perfect first Plastic Pipe project, and a great way to begin to develop your skills in this direction. This is a beginners level project. On all of the projects we offer as Project ePlanSets, working slowly, and carefully will help

help you to build a project that will demonstrate your fine craftsmanship. If you can do that, then you will learn and understand many of the basic skills required to successfully build a variety of the Plastic Pipe Projects we offer as Project ePlanSets.

This is a complete and easy to follow Project ePlanSet, including instructions on how to build this project and some basic information on where to obtain finishing ideas, such as about the simulated marble finish we used on our prototype.
You will notice on sheet 3 a complete parts list with color-coding so you can easily identify each part on any drawing sheet. All of the Pipe and Fittings used in this Project are made out of 3/4 inch diameter white PVC Schedule 40 Plastic Pipe and Fittings. (We did not use

the 3/4 inch beige CPVC Plastic Pipe or Fittings.)

We suggest you read through everything in this Project ePlanSet before starting to work. It may save time and energy later.

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 1 of 9

Projected Views & Overall Reference Dimensions

The overall dimensions stated here are for reference only. The critical dimensions are the lengths of pipe you must cut from the Pipe Cutting Table on Sheet 3, plus the Table Top dimensions are detailed on Sheet 6.

19-1/16

21-13/16

10

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 2 of 9

Complete Pipe Fittings List & Pipe Cutting Table

Exploded Assembly View
Table Top

B D

C
A

B
E B D B E B D C

Pipe Fittings List Schedule 40 Dia.

Color ID Qty 16 8 4 1 Description Tee Straight 900 Cap Elbow 450 Cross Straight 900

Pipe Cutting Table Schedule 40 Dia.

Code
A B C D E F

Qty
8 12 4 4 4 2

Length
1-13/16 2 9-3/8 7-9/16 3-3/4 19-7/16

Table Top
MDF (Medium Density Furniture Grade Particle Board) 12 x 24 x
Sheet 3 of 9

Total Length Needed = 15 ft.

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End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

Getting Started
Decide on Your Finish First
One of the first things you need to do is to decide how you are going to finish your project. Not only do you need to decide on color, but also will you brush or spray on the finish? Or will you do a simulated marble finish? If you are going to brush paint or spray paint your project, the best thing to do is to sand, scuff and degloss all the Plastic surfaces using 400 grit sandpaper before priming. This must be done in order for any paint finish to adhere to the plastic. The easiest time to scuff sand the pipe is before you make your first cut.

You should start by simply peeling the stickers of all the Pipe and Fittings, and then clean all of the printed lettering, clean off the glue from the stickers, plus whatever else by wiping all the parts down with a rag and lacquer thinner. The glue for the labels must be removed with a solvent like lacquer thinner if you dont, it will mess up your finish later. The best time to scuff sand the pipe is before you make your first cut. This is the easiest and best time to take care of these details.
Just before applying the finish, you should do the same wipe the entire project down with a rag dipped in lacquer thinner. Then apply a Plastic compatible primer followed by your choice of finish. To learn more about applying a simulated marble finish, you may want to order the Faux Marble Craft Plan Project ePlanSet from our Website at www.ePlanSets.com.

Preparation of the Pipe Fittings

Pipe fittings are injection molded. This requires the craftsman to remove all the flashings, and stubs from the sprues, gates, risers and flues. Knockout bosses, manufacturers risers logos, and parting lines all need to be filed or sanded flush and smooth to the contour of the fitting.

Using Plastic Primer and Plastic Pipe Cement requires a lot of fresh air ventilation. Do not breathe the vapors. Do not smoke while using the glue. Do not use in any area where there is an open flame or source of ignition. Avoid eye and skin contact. Wear safety glasses with side shields or goggles and rubber gloves.

~ CAUTION ~

Gluing Tip - Use PVC Primer

Priming joints with PVC primer you will later glue, makes for much stronger joints. If you use a colored primer, like purple, you can see that you prime the entire joint surface. About the only time you dont want to use a colored primer on your project is when you will simply use a clear coat finish.
Copyright 2007-2011 The Douglas Group. All Rights Reserved.

End Table

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Sheet 4 of 9

Some General Notes

Our End Table project involves many steps, each of which is relatively easy on an individual basis. The sequence of performing these steps is important, and, in some assembly procedures, you must do a number of things all at the same time. If you have had experience in gluing up Plastic Pipe plumbing projects prior to this Project, some of our procedures here are very different from traditional means. Be careful to read and follow specific directions on making each assembly.
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Tools you will need

Large Miter Box with Hand Saw.

on Sheet 7 for more information.)

(See the text

Finishing Sander Files & Assorted Garnet Sandpaper Try Square

~ Please Note ~
The PVC Pipe and Pipe Fittings used to build this Prototype End Table are schedule 40 and inch diameter. Fittings are likely to have minor size variations from one manufacturer to another. Even though they may all still be in compliance with ASTM D 2466, there will likely be dimensional differences, which you must allow for, These differences are not detailed in this Project ePlanSet. This may mean your finished project may not look exactly like what is depicted here.

Craftsmanship How To
Before you apply any primer or glue to any joint you should completely dry fit the entire project. By doing so, you can readily see if things dont line up. You then have the chance to make corrections without any embarrassment.

Sanding Plastic generates a fine dust. We suggest wearing a filter mask over your nose and mouth so the dust doesnt get into your lungs. Plus, we suggest wearing eye protection to protect your sight.

~ CAUTION ~

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 5 of 9

The Top
The End Table Top is symmetrical about both its vertical and horizontal Center Lines. The top is cut out of 3/4 thick MDF furniture grade particle board. An elegant alternative would be to cut the top out of Plexiglas, or even real glass. If you can find it, you may even want to try some smoked Plexiglas, for a touch of added sophistication. Or, you may even want to go with some Plastic much thicker, or even real glass depending on what your budget will allow. Once the top is completely cut out, mark and center punch the hole locations. Use a compass to draw the corner radii before cutting them. Drill the holes, route the cove and sand the top with progressively finer and finer sandpaper. When finished, the Top simply sets on top of the Plastic Pipe Table frame. You may want to get some small round peel-and-stick pads for the Top to actually set on.
3/ 8

cove

3/

4 thick

3/

12 6

10-1/4

11-3/8 20-1/2 23-3/4

1- 5/16 dia 4 holes

4-11/32 8-11/16

1- 5/8 rad 4 corners

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 6 of 9

Some Notes on Craftsmanship

This project requires you to make square cuts, to the exact length specified for each piece of pipe you cut. Tolerances on cut pipe lengths are plus or minus 1/32. Each time you fit a pipe into the bell of a fitting, it should bottom out, or be pressed in until it cant go in any further.
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~ CAUTION ~
If you use power tools in your woodworking shop, be very careful. Plastic does not cut nor machine anything like wood. Most woodworking saw blades, drill bits, and cutting tools are aggressive on Plastic, and will grab the Plastic possibly pulling you into harms way. Saw blades with very fine teeth work best for cutting Plastic.
Another alternative is to use a power miter saw or chop saw. This may be more difficult to control, and it will give you a rougher cut. If you go this route, it is best to use a fine tooth blade. Also, be aware, even if you are using a 10 diameter blade, there is not enough clearance to cut through a 4 Plastic pipe. Generally speaking, using power tools requires skills quite different from working with wood. If you use power tools, set your speeds fast and take your cuts very slow, either feeding the work into the blade, or feeding the blade into the work very gradually.
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Making Square Cuts

The best tool to make your square cuts is a miter box fitted with a fine tooth hand saw. Even then, a true, clean square cut may need to be cleaned up a bit with a keen eye, a try square, and a sander. If you know you are going to have to clean up the ends after sawing, then allow a little extra in length for each cut maybe an extra 1/16 or so. You may have to experiment improving your cutting skills as you go. If you plan to do more and larger Plastic Pipe Projects after this one, then you should probably purchase a large, quality miter box with a fine tooth hand saw, unless you already have one in your shop. 4 diameter Plastic pipe actually measures about 4-1/2 outside diameter. Many miter boxes will not have that capacity.

Mark Each Piece as You Cut

As you cut each piece of pipe, its a good idea to mark the part ID, and the finished length, right when you take it out of the miter box. You can write this information on a piece of masking tape and stick it to the cut piece of pipe. Your assembly will go much smoother if you keep things well organized from the very beginning.

We have made every effort to make sure every detail, every dimension and every specification in this Project ePlanSet is accurate. We design and build our projects in order to verify all the information included. However, we are human. Errors are possible. We regret any errors that may be present, but cannot assume any responsibility for our unintentional errors. You should always dry fit assemblies and sub-assemblies to check for accuracy before applying any glue, making any adjustments as needed.

~ CAUTION ~

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 7 of 9

Assembly

Top Frame Section

Prime and glue each joint as shown.

Bottom Frame Section

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

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Sheet 8 of 9

Final Assembly

Assembly of Top & Bottom

Once the base frame is completely assembled, finish scuff sanding all the Plastic pieces. Wipe down with a tack rag and apply your primer. Paint or marbleize the top and the base frame separately. Once the finish is dry, the top simply rests on the frame.

Fit the Top

Have fun! We really want to see your results and hear from you. Please send pictures of your finished projects to:

Webster@ePlanSets.com
We really do care, and we want to see how your projects turn out.

End Table

Copyright 2007-2011 The Douglas Group. All Rights Reserved.

www.ePlanSets.com

Sheet 9 of 9