I the previous post we covered how to build the octagon ring. The skirt will be built right underneath.
On with the tutorial:
Keep in mind that some tools are needed to do this project and if you don’t have it then you will need to buy it or rent it.
Building and Attaching the Octagon Skirt
Here we’re just going to walk you through building the skirt. Using a biscuit joiner to put it all together. And finally attaching it to the Octagon Ring.
Get out your eight pieces of 1×6 that you ripped from your bull nose.
If you have a radial arm saw, make a 3/4″ notch on the end of all eight pieces. Only remove 1/4″ of the board.
Those without the radial can use your table saw by making two rip’s to get the same notch. Make the cut on the already ripped side of the board so the you will have a finish side on the bottom of the skirt.
Time to fit all the skirt pieces to the octagon ring. Pick a side, any side and using your compound saw cut a 22.5 angle on one end. Cut two test pieces for both the left and right side of the skirt. Using the test piece fit a skirt onto the back of the bull nose.
Use a square to fit the opposite end and cut it with a 22.5 angle.
Go around the ring and cut all the skirts in place. Mark each side to each skirt.
Dry fit the skirt in place and make sure all is tight. Drill a countersink screw hole on the back of the skirt down where you will connect it to the bull nose. Make three holes on each board (ends and middle) and follow it with a pilot hole into the bull nose .
Watch not to drill thru the bull nose.
Time to get your joiner back out and make your cuts on the skirt pieces. I setup a 22.5 angle jig for this. Make biscuit location and cut both side. You will only be using one biscuit per joint.
Notice how I use a shim (1/4″) to pickup the joiner. You can adjust the the plate but since this is the only time I would use this height I just use a shim.
Lay out all the pieces and get ready to glue, screw and set.
This part requires that you have a ratchet type tie down straps (18′ minimum) and clamps. Work here will have to go fast so if you can find someone to help do it.
Start with any end and apply glue. Jump right into the next piece and start connecting it with the biscuits on top of the octagon ring. Continue till you have all eight skirt pieces glue and sitting on top of ring.
Apply glue to the back of the bull nose. Now push and force the skirt down into the ring behind the bull nose.
Once down wrap the strap around the skirt and start to tighten up the strap. Use clamps to keep the skirt down on the ring.
Notice the paper towels at the skirt joint. Clean up the glue as it comes out the joints.
Screw in the bottom of the skirt and use clamps to keep the board down. Once screwed you can remove the clamps. Let sit and dry over night.
What I did while waiting for the glue to dry was flip the octagon over and did some palm sanding with 120 sandpaper.
Your skirt should be nice and dry some remove the strap. Looks nice don’t it.
Flip it back over and get your router. Use a 3/8″ quarter round bit and round off the bottom of the skirt.
Careful to keep level and balance when working the router around the bottom of the skirt. After you router the bottom sand the skirt with 120.
That’s all for today.
In the next Phase we’re going to cover the Play area and Sub Table.