Walnut Sofa Arm Coaster
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Jig Saw
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1x6 Wood Plank
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Pencil
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Speed Square
Wood Rasp / File
Clamps
Radial Arm Saw Or Other Circular Saw
A Flat Sofa Arm
Wood Glue
Wood Sealer And Applicator
Measure the width of your sofa arm, and deduct some to avoid knocking elbows.
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Decide how long you want the side. Mine is 3 inches.
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Measure and mark the length of your side + thickness of your plank
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Extend your line with a square
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You should cut to “save the line”
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The finished piece is on the left
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Wear proper PPE and be safe. Safety is you #1 priority. Make your cut
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Check your work
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Measure the top dimension you want + the width of the side
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Measure for your box joint pins on the top piece
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My pins are 1” from both sides, and each pin is 1” wide
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Use the jig saw to cut out the waste
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I cut both sides, then at angles in between. Color inside the lines
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Use a wood file to clean up the joints, or a chisel
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Align the the side with top & trace the lines onto the Side
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Remember how your pieces are to align, and mark if needed
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Be careful to mark the negative space so you know what to remove
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Cut out the waste
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Sorry for the misaligned shots, my “camera mount” was getting vibrated around by the jig saw
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You can start to see how the joints will fit
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Check your alignment and look for areas which are tight
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Remove small amounts of wood & keep trying the joint until it fits snugly
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Look for high spots too flatten
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Use your square to check various alignments
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It’s starting to look good, but keep at it
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Apply wood glue to all joint surfaces that touch on both pieces
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Check your alignment is square. Clamp if needed
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If you have gaps, mix some saw dust with wood glue and fill the gaps. Huge mess, but will sand off
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Sand from 80 - 150 grit or higher (I went to 220)
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“Break the edge” by rounding over with 150 or higher sand paper until edge feels soft
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Apply sealer and let it dry per instructions
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Thanks for watching
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