So my wife asked me to make something that my 5 year old son could use with his Lego and I wanted to make him one of those Lego tables with drawers but honestly had no where to put one so I did some research online and found this nifty little project where it is basically a tray that you can set on the floor and build on and when it is not in use he can just slide it under his bed.
I didn’t make any plans for this and pretty much made it on the fly using some scraps I had lying around the shop I did need to get some materials and they are listed in this post.
This project should only take 3 stages and Part one is below:
WHAT I DID TODAY
Cut pieces to size
Assembling the tray
Router Time 2.0
A little paint
I went to my local big box store and Target o get some supplies and here is what I got
(4) Lego base-plates (10”x10”)
24” x 24” x 3/4” plywood panel
I used scrap oak and poplar but you will need a piece of 1”x2” x 8” lumber.
(2) Utility handles
Pocket hole screws 1-1/4”
CUT PIECES TO SIZE
In order to figure out what all the dimensions needed to be for all the parts and the plywood panel I needed to open all the Lego base-plates and get the overall size and it worked out to 20-1/8” square.
so I cut the 3/4” plywood panel to 20-1/8” square on the table saw, and then cut all the wood strips which make up the frame that surrounds the panel.
POCKET HOLE TIME
In order to attach the outside frame pieces to the base I needed to added a joinjery system so I decided to keep it easy and just add pocket holes so I just add screws to attach the sides while the glue sets up.
I use the Kreg K4 jig and made a station for it where all my accessories for the jig are stored. So I placed 4 pocket holes on each side, below you can see the finished panel and the K4 station.
I actually used the router twice in this build, I wanted to add my sons name to the outside edges of the frame so I used my Palm router to freehand his name but before I did that I needed to add some outlines of where I wanted to position the name.
ASSEMBLING THE TRAY
I took the following steps to assemble the tray:
Added glue to the inside faces of the 4 frame parts
Assembled them in the clamping jig
Inserted all the pocket screws into their respective holes
ROUTER TIME 2.0
I also wanted to add a round-over to all the edges of the frame so that my son didnt hurt himself on the tray, so I took it over to my router table with a round-over bit in the router and did all the outside edges, then I used my palm held router to get the inside edges of the frame and it came out great but tomorrow I will be sanding it down to make it even smoother to the touch.
A LITTLE PAINT
I wanted to add some black paint to the carved out letters for my sons name so I used some I had on hand and let it dry over night as I will be applying a polyurethane coat tomorrow. I will be sanding this whole surface down tomorrow which hopefully will make his name pop on the tray.
HOW I LEFT IT!!!
Below shows a picture of how I left the project today
Sand the entire project
Apply the polyurethane prob 2-3 coats
Apply the Lego base-plates using Gorilla Glue