The box table section of the seat was made by laminating three pieces of walnut to form the top section. This was cut with a lot off tolerance, and routed a rebait on three of the four sides (as the tale top had to fit flush with the upholstered sofa and therefore would have a curve, spanning from the right side around to the back of the walnut section).
Once the sofa arrived back from the upholsterer, i double checked that my measurements were right – taking into account the width of the solid walnut skirt that would sit a long the front – and used a piece of cardboard to get an accurate shape of the curve.
This cardboard curve was then cut out and transferred onto the walnut table top. The curve was cut with tolerance and then sanded down to the line, the side and front panels were then glued and clamped into the rebait within the table top. The side panel on the right was cut and sanded across the grain, where it protruded from the curve. The length and curve was continually checked against the seat, to ensure it would fit snugly, throughout this process.
The clamps were removed and the box sanded through the grades as a whole box. Any dirt or remaints were blown off with compressed air and danish oil was applied.
M10 threaded rod was inserted into the legs – 5 cm deep leaving 4 cm protruding from the top of the leg to insert into the t-nut. These were twisted into the leg with araldite between the threads to ensure there wouldn’t be any movement of the thread inside the leg.
The sofa was tipped onto its back to insert the legs, twisted in one by one – roughly to the desired angle, then propped back upright, so that the legs could be fully twisted in to the correct angle.
The solid walnut skirt was attached via a piece of pine screwed into the back of the walnut along the bottom edge, this was then placed underneath the base of the seat then screwed upwards from the underside of the sofa to hold the skirt in place.
The table section was placed into its space to check everything fit well, then removed. Gorilla glue was applied to the bare ply left on the sofa where it would come into contact with the table top. The glue was placed here instead of on the table top, as it might come off on the fabric of the sofa during placement. The table top was weighted down and clamped until the glue was set.