I had a unique request to create a Lego table from a client and was intrigued. We started talking about design options and I think it turned out pretty cool.
Plan
The client had a great idea already and I just had to add the details of the table top. The client had already purchased (4X) of these IKEA cabinets to use as the base. So my job was to create the table top and figure out how to get it into the basement. It was so large, it had to be made from two pieces of sheet material and then joined together at final location. I am using the knockdown fasteners from Festool and some dominoes for alignment. I have found out, the hard way, that Lego bases are slightly larger than 10″ x 10″ and more like 10 3/32″ square.
YouTube Video
Materials
I chose to use 3/4″ MDF (2 sheets) for the Lego Table Top and 6/4 maple for the edging. I used STIX Primer and actually used two different paints (Command and BM Advanced), which we will get to later. In order to join the tops together I used some dominoes and the festool connectors.
Cutting Sheets to Size
For this design the edging will overlap the ‘work surface’. So I had to account for that when cutting the sheets to size. I think I used a 3/4″ as the anticipated overlay and laid out my cuts on the MDF. Then got to work with my track saw. The width below (61 3/4″ ) is not wide enough once the edging is added. 62 3/4″ or 62 1/2″ is better. The reason the sheets are asymmetric is to allow the “long edge” to completely bridge the gap between the cabinets and rest on the other side. My concern was that someone would sit or lean on the unsupported area and the joint between the two sections wouldn’t handle it.
Once I cut the first sheet, I use it as the template for the second sheet. Now we have to sheets and our base.
Edging
There are 3 different edge types on the lego table top
- Simple Edge Band on 5 Edges that are ‘internal’
- Large bullnose edging on the external edges
- The external edge gets a groove to accept the table top
- An internal frame that sits on the table top for the center opening
- It is removable for easy cleanup
The external edging and internal frame start out the same exact way. After milling, I rip it to 1 1/2″ wide, then create a big 3/4″ x 3/4″ groove. For the internal frame, I cut off one of the remaining sections to create a big rabbet.
Gluing on the Edging
I had to start by gluing on the simple band edging first since the external groove continue onto this edge. Confusing, but pictures may help
Once I got the simple edge glued into place, I have to size my external pieces and cut a small tenon on each side of the “end” edge. That tenon will go into the groove of the other edging. Once that was cut, I glued on the external edging. All of the external edging received a 3/8″ (I think) round over on top and bottom.
The internal frame was made by cutting 45 degree cuts on each end and making something that resembled a picture frame. I am pretty sure I cut the round over on the individual pieces before gluing up the frame. The frame also got some splines added to it for strength
Sand and Paint
I did create the domino mortises at some point in the lego table top, but then it was time for sanding, patching, painting. One of the larger challenges with this job, was how I could paint both sides of these huge tops. I didn’t want to paint one side and wait for hours before I could flip it over. So, I came up with a unique solution using the existing domino mortises and connector system. I added two pieces of MDF to each leg and then screwed a big foot to the bottom. I put this onto a furniture dolly to wheel around.
I had a very tough time getting the Command pain to lay down smooth. I kept getting little dry bits, like the paint was drying too fast or drying as it hit the surface. It was hard to lay the paint down thick when in vertical orientation. So, I switched back to BM Advanced and got a nice smooth coat.
Delivery
The table top is very heavy, so it is not screwed down to the Ikea bases. The bottom edge of the table top stops it from shifting front to back. I added two little strips on the inside to keep the table from shifting side to side.