Step Task Part No. to use

Time, Minutes

Tools to Use Link to Spec.

Quality Control Safety Notes

1 Mark out the first and second circle (Part 1 and 2) and the centre points for the holes.Mark out both squares from the centre point of the circle.See Working Drawings for dimensions

1,2 45 Steel Rule, Marking Knife, Try Square, Pencil, Plywood Guide, String

Recheck the sizes are correct against against the Working Drawings

2. Mark out the second circle (Part 3) and the centre points for the holes.See Working Drawings for dimensions.

3 45 Centre Punch, Pencil, Marking Knife

Use first circle as template . Double check measurements against Working Drawings

3 Make a MDF Jig for the cutting out of both circles, file and smooth

Cut out all circles for each part

1,2,3 180 Power Router, Straight Cutter, G- Cramps, Bastard, Second Cut and Smooth Files, Fine Sandpaper

Try guide on spare wood first, use the correct router cutter, use jig to rotate router from centre point to cutting edge

Use both hands, advance steadily, withdraw after every operation, always unplug before changing cutters or fittings, wear safety glasses, no loose clothing, hair, jewellery, always clamp work securely

4 Drill pilot holes for the cutting of the Square hole from Parts 1 and 2. File & SmoothCut out squares from both circle – NOTE: Check dimensions as Squares are different sizes!

1,2 120 Pillar Drill, HSS Drill Bits, Bastard, Second Cut and Smooth Files, Fine Sandpaper

Use the machine guard, wear safety glasses and no loose clothing when drilling, clamp work securely, always remove chuck key after fitting drill bit

5 Make the holes in all circlesSee Working Drawings for the Drill Bit Sizes

1,2,3 45 Pillar Drill, HSS Drill Bits,

Check Dia. Of holes and Dia. Brass Tubes with Vernier Calipers

Use the machine guard, wear safety glasses and no loose clothing when drilling

6 Mark out centre points of the 4 x Joint Sleeves

7 Using increasing sizes of drill bits, make the holes……… in each of the Sleeve Joints

8 Apply Stain and Varnish to Parts 1,2,3…. And leave to dry

1,2,3 60 Medium Oak Stain

Step Task Part No. to Use

Time, Minutes

Tools to Use

Links to Spec.

Quality Control Safety Notes

8 Measure and mark out the correct lengths of the Brass Tubes See Working Drawings for dimensions

15 Scriber, Engineering Rule

Tilt Scriber away from rule when marking out. Check the Dia. With a Venier Caliper. Check the length measurement with the engineering rule

Wear gloves when handling as it may have sharp edges.

9 Cut the Brass Tubes to the correct length

60 Hacksaw Use protective wood in engineers vice when cutting, check tension on Hacksaw, make cut in the unwanted material

Wear safety glasses when cutting metal, tighten correctly in vice

10 Drawfile, Deburr and smooth ends of Brass Tubes

60 Flat Files (Various)

Step Task Part No. to use

Time, Minutes

Tools to Use

Link to Spec.

Quality Control Safety Notes

11 Mark out the circles and centre points of the holes for the Brass Circles (Parts ? And ?)

12 Drill pilot holes for the cutting of the square ( Parts ?) Cut out the square from Brass Circle

13 Cut out both circles and all holes to size neededSee Working Drawings for dimensions and Drill Bit Sizes

14 Using the correct adhesive bond Parts 1 and 2 tightly together and leave to dry

15 G Clamp, protective wood, PVA Adhesive, Applicator

Use protective wood when clamping to protect table top, follow manufacturers instructions carefully

15 Using the correct adhesive bond both Brass Circle Parts ? And ?) to the now joined Parts 1 /2 and Part 3

30 G Clamp, protective wood, Epoxy Resin Liquid Adhesive, Applicator

Use protective wood when clamping to protect table top, follow manufacturers instructions carefully

Step Task Part No. to use

Time, Minutes

Tools to Use

Link to Spec.

Quality Control Safety Notes

16 Now assemble and bond (using the correct adhesive) each of the Brass Tubes to the Table Top (Part 1/2) and leave to dry

30 Epoxy Resin Liquid Adhesive, Applicator, Spirit Level

Check Table is at 90 degrees to floor. and table surface is level. If not re-file Brass Tubes and repeat.Ensure both sides are touch dry before bonding

17 Now assemble and bond the Middle Table Top (Part 3), the Brass Tubes (Part ?)and the four Joining Sleeves (Parts ?) to their correct position and leave to dry.See Working Drawings for Correct Position and Dimensions

30 Epoxy Resin Liquid Adhesive, Applicator, PVA Adhesive, Applicator, Spirit Level

Check Table is at 90 degrees to floor and table surface is level. Check measurements against Working Drawings

Step Task Part No. to Use

Time, Minutes

Tools to Use

Link to Spec.

Quality Control Safety Notes

18 Using 2D Design software draw the design of the Chessboard

120 2D Design Software, PC

Save work and create new files as the design progressesCreate Back-up copies

19 Using 2D Design software draw the design of the Backgammon Board

120 2D Design Software, PC

Save work and create new files as the design progressesCreate Back-up copies

20 Laser cut and etch the Chessboard

2D Design File, Laser Cutter, PC

Follow instructions and cutting guides carefully

21 Laser cut and etch the Backgammon Board

2D Design File, Laser Cutter, PC

Follow instructions and cutting guides carefully

22 Using the correct adhesive bond the Chessboard and Backgammon Board together and leave to dry

15 Liquid Solvent Cement (Tensol), Clamp, protective wood

Use protective wood when clamping the parts for bonding

23 File and Smooth the bonded boards

Smoothing File, Fine Sandpaper

Check you are using the correct file, don’t over file

24 Place in the correct position the new bonded board on the assembled tableSee Working Drawings for information

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