Custom Oversized Wood Work Desk - April 2023

Overview

This project began with the need for a bigger workspace. I had owned a basic ikea desk for most of my life, but it just didn't hold up to my high school demands. The desktop was small, barely fitting more than 2 sheets of paper and a laptop. Combined with the wearing and scratched surface, I knew I needed something new. Junior year finals were coming soon, and senior year was just around the corner, so what better time to build a desk, than right now?

I started by searching the internet for inspiration. I wanted legs that I could weld, so stainless steel was on the menu, and I wanted legs that were low profile, and wouldn't get in the way. I ended up choosing a 4-point stand with a sigma shaped side profile. I looked for wood that was a medium shade, as I didn't want imperfections to be immidatley noticable, but I did want a nice contrast to the dark metal.

I ended up using 2" x 12" walnut, which I cut to 3 42" long sections. I drilled holes and used fluted dowels with wood glue to attach each section. Even though I clamped the wood pieces together, there was still a noticable gap between the planks after the glue dried. Thus, I decided to use a router to route a 1/4" channel along the seams. Then, I friction fit a 1/4" square stainless steel key rod into each channel. These would add a nice accent while hiding the noticable seam. Per a recommendation from my local wood shop, I sealed the desk with a water based top-coat. I applied 3 layers using a roller, and sanding with 220 grit between coats.

For the supports, I cut and welded 1 1/4" square tubing into 2 seperte pieces, each shaped like a "w". I then welded a cross beam at the far top edge, to connect the two supports. At each of the top 4 corners, I welded a 3/16" plate section, each with a 5/16" hole. The bottom far two corners got a 17/64" hole that I tapped for a 5/16" bolt. I sanded and primed the stand, and finished it with two layers of a rustoleum textured black spray paint.

Final assembly included lining the table top up on top of the stand, marking where the mounting plate holes meet the wood, and drilling 4 holes, one at each mark. This creates pilot holes for the 5/16" lag bolts I used to attach the top to the stand. I also drove a 5/16-18 bolt into each tapped hole, creating two adjustable legs.

What I Learned

• Designing furniture to meet user needs
• Welding and finishing stainless steel for clean, strong supports
• Woodworking techniques for routing, joining, sanding, and sealing
• Incorporating helpful features like adjustable legs for practicality