I decided to set the storage cabinet project aside for a few hours today, to upgrade the knock-down workstation. I realized just how sharp the edges on the workstation were, when I tore off a chunk of my finger, the other day, catching a corner. Not a major injury, but a painful one. I am going to go ahead and add rounded over rails to all the edges that I, or my material, might bang into.
I started by ripping down some scrap maple to match the thickness of the legs, and the width of the top rail.
I put my 3/4″ round-over bit in the router table and ran all of the leg pieces through twice to create a half round on my 1″ thick maple rails.
I cut a 45 degree angle on each of them, and started laying them out around the legs. I marked the corners and cut the other 45 degree angles.
I applied glue and clamped the trim in place, then shot 2″ brad nails in to hold everything in place. I didn’t bother measuring the notch, I just ran the trim across it.
When the legs were wrapped with trim, I took them over to the band saw and cut the 3/4″ notch out. Next, I set the top rails in place and cut the notch wider to accommodate the top flange on the rails.
With the legs all trimmed, I set the maple cap for the top rails in place, and counterbored some 1/2″ holes half way through the cap.
I attached the caps with 2-1/2″ pocket hole screws. The top caps will be sacrificial, so they don’t get glued on, when they get cut up enough, I will just pull them off and add new ones.
The nest step was to add a 3/8″ round-over to the top caps. This was easily done with a router after the caps were secured. When it was done, I ran the orbital sander across everything with 80 grit paper to ensure that all of the corners were round and smooth.
I shouldn’t tear off any more chunks of skin, and the rounded base of the legs should work better than the squared-off plywood edges. They would have torn up or de-laminated over time. The maple should last a lot longer.