For years, Mrs. Jean Charles Black, Head of Costuming at the Ryerson Theatre School, had to make do with university cast-offs and found furniture for her costume shop. Gradually, as the budget allowed, we replaced each of the old hard-topped lab tables with attractive and fully functional cutting tables. The tables are based upon a design first developed by Mrs. Black and Bjarni Christiansen when setting up the wardrobe at Canada¹s Wonderland. We later modified the design to suit a teaching wardrobe, providing the maximum work surface and storage space within the footprint of the table.
(A view of one of the pedestals: 115k image)
A large lay-out surface is the predominant feature of this furniture; it combines a non-skid, pin-able surface with a straight, hard edge for pattern drafting. The top sits on two large pedestals, each containing three large bin drawers. Full-extension hardware provides for access to the entire drawer. Situated between the pedestals is a knee-space with a three-compartment storage area ‹ accessible from either side ‹ for patterns, T-squares and other long items. Both pedestals have four 3" swivel casters, two of which have locking mechanisms to hold the table in place. The four casters allow the pedestal to be moved around independent of the rest of the table during transport and assembly.
Construction details are fairly simple. These tables can be constructed in any moderately equipped shop. The only major tools needed are a table saw and a router equipped with a 3/4" straight cutting bit. Optional tools are a stacked dado cutter and a biscuit joiner. Dimensions are modular, so the elements can be cut from 4¹ x 8¹ sheets with very little waste.
The pedestals are a simple three-sided box construction. The back panel is let into a rabbet on each side panel, and the front is held square by the 1x2 drawer separation let into stopped dados on each side panel. Two lengths of 2x4 are also let into stopped dados, and half-lapped to receive the two 2x4 foot rest/stretchers, which serve as mounting positions for the casters. 3/4² plywood corner blocks mounted in each corner near the top of the pedestal serve to square the unit and provide a fastening point for the top. The two exposed plywood edges of each side panel are capped with 3/4" by 3/4" pine.
The pattern storage compartments are constructed of 1/2" ply to conserve weight. The dividers are let into rabbets and dados in the base, and two pieces of 1x3, notched into the walls, keep the dividers perpendicular to the base. The 1x3s over-hang each side of the unit by 3/4" to nest in notches in the back panel of each pedestal. This supports the unit over the knee-space and is secured by bolts and nuts.
The drawers are also constructed out of 1/2" plywood with a 3/4" plywood face. Weight and space conservation are the determining factors here. The full-extension drawer hardware is a particularly nice feature, allowing easy access to the entire drawer. Since the 1/2" plywood box construction doesn¹t allow for a dado into which the luaun bottom can slip, this bottom piece is supported on each side by a 1/2" by 1/2" ledger strip. A nice finishing touch is to cap the exposed edges of the plywood fronts with strips of pine.
The top is made of a full sheet of 3/4 inch plywood, with the cork work surface glued to that. The wood edge is made from 2x2 pine, rabbetted to accept the thickness of the ply plus cork top and mitred at each corner. If the budget allows, use a kiln-dried straight-grained hardwood to improve the durability of the edge as a drafting guide. The top is centred on the pedestals by 1x2 ledgers on the underside of the ply, and secured with wood screws through the corner blocks of each pedestal and the 1x3 spreaders in the pattern compartments.
In the finishing stage, I recommend sealing each unit inside and out with shellac or a good sanding sealer. The top coat should be a good quality latex enamel, for durability and washability.
I see this particular design as having both versatility and a long work life. Once the table is disassembled, it would fit easily into a standard cargo van: a useful feature for companies that must set up a costume shop in temporary and remote locations. With some alteration to the pedestals to provide for locking mechanisms or doors, they could become useful road cases which don¹t take up extra space after you reach your destination.
(Another view of the cutting table: 92k image)
Cutting List
Three sheets
One sheet
Two sheets
Sixty-four feet
Twenty-four feet
Six sets
Twelve
Eight
Forty
One piece
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