WOODWORKS: INTERMEDIATE PROJECT 2002-2003 TABLETOP SOCCER you like fast ation fun, bee's a homemade foosball game thal give everyone hours of enjoyment. + its hardwood construction i tough enough for los of overtimes, and wien te game is finaly over, it stores compactly, Just ip out the dowel rods, put them insie the box, and se the gare on a shelf ‘To make the game easier to build, you can devise jig that simplifies the dificult task of ataching the rectangular players and goalies to the dowel rods. ‘To save you some legwor, the Shopping List ells where to get some of the hardero-find pieces, but you'l ind almost everthing ese you need aa home center or lumberyard ‘This gume gives intermediate woodworking students the opportunity to lean a mumber of important, basic skis, including measuring, cling, ‘marking, diling, routing, slung, clamping and mitering, And alter you build it, you'l lar how to apply and use finishes to protect the wood and Keep it looking beaut,‘CONTINUED - WOODWORKS INTBRMEDUTE PROJECT 2002-2003 TABLETOP SOCCER TOOLS REQUIRED Hand Tools Miscellaneous =Two 4’ bar clamps ~ Pencil — Iwo 6" C- or other small clamps — Salty gasses = Screwdiver ~ Carpenter’ gue Combination square = Gloves for finishing Power Tools a Clean, lint-free cloths ~ Table saw and dado blade Mineral spits (roi based finishes) ~ Scroll or saber saw 3 ae ay — Wateflled metal coniainer with ight-fiting id Router with a 1/4" ee = Minwax* Polyeryic® Brush, or good quality synthetic bristle brush for Water-Based ~ Belt sander with a 60-rt or cnarser tans and Finish, or Minwax® Wood Finish Stain Brush, Minwax® Polyurahane ‘Neon Mata ak or ond ov bl idoing ‘pec sre ons rot and fn me eye alae ie (Shes nd ata sres alo tse rel aha ps, 3/4 x 45/16"x 20° srap plywood (routing jig rear suppor) 3/4" x 2-1/8" x 20” scrap plywood (routing jig on! suppor) 3x 1-1/2" x 207 srap plywood (routing ig nce) "77x39 nylon mesh (goal nets; see Shopping Lis) sanding belt 2 " Mec ci, 1/16 spade band gro god quay natural este brush foro aed sts and ashes 3/8". plug cuter ~ Hot-lue gun SHOPPING LIST CUTTING LIST tem Quantity] [Key] Pes. [Size & Description 17x 6°x8" oak 2 [A_[2 | 34*x5-172" 41" oak (Side) [ 34" x 24" x 48" oak phywood 1 B_ [2 | 345.172" 18" oak (ends) 23/4" dia. x36” birch or maple dowels_|4 (c_[4 | 34" 47x 5° oak (ramps) 3/4" dia. x36° walmt dowels——_|4 D_ [2 | Wat 2°x 2-1/2" oak (goalies) VA" dia. x9-1/2" birch dowel 1] [B[i8 [ax 14x 2712" oak (players) | 1-1/4". birch ball 1 IF [4 | Va"x34"x9" oak (nel supports) No. 6 1-14" drywall serens [12 G_|4 | 3/4" dia x29” birch dowels (player/goale rods) No. 6x 3/4” brass ahead serens | 12 [4 | 3/4* dia x29" wait dowels (layer/gole rods) non-skid rubber fetwith screws | 6 [4 | 14% da x1 birch dowels (goalie rod stops) — rubber hand grips 8 [1 _[34*x 17° x41" oak plywood (laying ld) 12x 24 nylon mesh ne 1 [L|1 | 34*x7"x 20" scrap phwood (routing jig bas) M1 Nt Pt ie [2 WOOD FINISHING PRODUCTS ‘Recommended Finish Alternate Finish Prep: Minwax* Water Based Pre-Stin Wood Conditoner Stain: —-Minwax* Wood Finish" ** Sides and Ends: Golden Oak Stain: Minwax* Water Based Wood Stsin* ‘Base & Ramps: Golden Oak Sides and Ends: in Honeydew ‘Walnut Rods, Players & Goalie: Special Walnut Base & Ramps: n Green Tea Birch or Maple Rod, Players & Goalie: Ipswich Pine ‘Walnut Rods, Players & Goalie: in Wild Berry Ball: Minwax* Wood Finish” Pickled Oak Birch or Maple Rods, Players & Goal: in Natural Belge **ecyour coc of 8 inea* Wood Fis Sain ors) Bal: White Oak (ar aay color you prefer) "(ors Winaa* Wace Wod Sal of your cic, alae in sx Finish: Minwax® Fas-Drying Polyurethane Satin ‘wood tne ad 60 cat clas) Finish: Mimwax® Polyeic® Protective Finish Satin a‘CONTINUED - WOODWORIS INTERMEDLATE PROJECT 2002-2003 TABLETOP SOCCER BEFORE YOU BEGIN ‘Good craftsmanship begins and ends with good work habits, so make the followin steps part of your routine workshop practice. you have any doubis or questions about how to proceed with a projec, always discuss them with your shop instructor. * Carefully and fully review plans and instructions before puting tool to the project lumber. + Work sensibly and safely. Wear safety goggles when doing work that creates ying chips and sawdust; wear the approprite respirator ‘whenever making sawdust or working wit thinners or ther solvents * Atthe end of every work session, cleanup your shop area and put away all portable tots ‘CUTTING AND ASSEMBLY PROCEDURE 1. Cut pieces A through C and pieces F through Q to the dimensions sven in the Cutting List The goalies (D) and players (E) wil be cut to tino the goaie/player éawel-rd grooves late. When you cut the goal nes (Q), follow the weave ofthe mesh to help eut square pieces 2. Lay out and dri the rod oles in the sides (A). Counterbore and dill the drywall screw holes inthe ends (B), and il the screw holes in the net suppors (). 3. Using a table saw fed with a dado blade, cut the grooves inthe side and end pieces (A and B), then cut the rabbess onthe ouside ‘edges ofthe end pieces. Sethe fence so the rabhets willbe 3/4" wide ow To Cut A Wedge ‘Here's fast and simple war to cut the plywood routing jig wedge using your table saw. lamp 250” auiiary fence to the table saws fence. Make a 1/2" x 3/4" 2” riser block to hold the plywood piece at an angle to the fence. Se the ausiliar fenoe 3-11/16* away from the saw blade (use bade with a 1/8" ker blade), Tape the riser block to the plywood soit olds the plywood 1/2" away from the susan fence and cutoff the wedge. 4. Assemble (without glu) the sides, ends and playing eld (A, B and X). Take a close look at Figure A, then lay out the 5/16*-wide playergoai slots for insering the rods once everything i assem- bled. Note thatthe layout is diferent on each side. To avoid spiting the wood later when you insert the screws, il pilot hoes for the drywall screws that attach the ends to the sides. Then disassemble the parts, and ct the slos wi jgsam 5. Lay out and cut the goal holes on the ends (B) with a jigsaw. Sart by driling a 38-dia. hoe inside the cutout to insert the jigsaw bide. ‘Smooth the sawn edges with He, 6. Make the player/goaie groove routing jig next. Stat by cing the sliding wedge off part M, te routing jig rear support (Fig, B). Then ‘le and clamp the routing jig pices L through P together as shown in Figure . This jigs st fra router with a 6"-dia. base. I your router has a diferent diameer base, gu the routing jg fence (P) to the routing ig rear support (M) so the router bis centered over te rods (half the diameter of your router's bas) We devised this ig to make simple work of eutng straight grooves in dowel rods. I ‘not only save frustration, but ensures thatthe grooves line up straight along the dowel rod. The rod is held tight inthe jig by tapping on the ‘wide end ofthe sliding wedge. Then the base ofthe router is held against the fig’ fence asthe router bit is plunged ito the rod andthe ‘groove is cut A regular router works fine but a plunge router makes this job ease. 77 Measure and mark the jg routing guidelines relative tothe right end ofthe jig using the dimensions and lout shown in Figure Use a combination square to draw the lines across the jig front support (N), 8, Seta player rod (6) into the routing ig and liga the right end ofthe rod fush withthe right end of the jig Tap the wedge in place ith a hammer to hol the rod securely inthe i. Using a combina- tion square, transfer the routing guidelines from the jig tothe ro, Rout the thre player grooes using 1/4" straight router bit Cut te grooves slightly pas the marks draw on te rd. Do three of tn birch rods (6) and three ofthe walnut rods (H) this way. {9 Using the routing jig again, cut te goalie grooves inthe two ‘remaining rods (one groove per rod). Because the goalies are wider ‘han the players, mark the routing end points 3/8” wider on each side ‘ofthe centr player guidelines, Next, dil the rod sop () holes before you remove the goalie rods from the ji, 10. Using a table saw wit a regular rip blade, cathe goalies (D) and players (B) tothe dimensions given in the Cating List, and so they fi tght inthe grooves ct in the rods 1. Taper the ramps (C) using 2 60-grit or coarser sanding bet in your belt sander as shown in Figure D. Apply 2 couple of dabs of hot tue tothe underside of the ramp pieces to temporarily hold them to, scrap board. Clamp the scrap board toa worktable and sand the tapers. Use a putty knife 1 "pop" off the tapered pieces from the serap board, 12, Sand the surfaces ofall dhe parts smooth excep the outsides of the sides (A) and ends (B); this wil be done later. tart with 120-grit sandpaper, and finish with 180-grit sandpaper 13, Glue and clamp one side tothe playing fed (F) and et the glue dry. Then gue and clamp the other side to the playing fed. Before the give dries, ue and serew the ends (B) in place. You may need to loosen the clamps nea the edges ofthe sides in order to get the ends ogo on. 14 Cut 12 oak serew cover plugs using a 3/8" pg cuter. Glue and hammer the pugs into the counterbored drywall screw hols. Now fnsh-sand the outsides ofthe side and end pieces. 15. Glue the players, goalies and goalie rod stops () into thei rod slots. Also glue the ramps info the corners ofthe paying field. Sand. smooth al the sharp edges ofall the pars[CONTINUED - WOODWORKS INTERMBDLITE PROJECT 2002-2003 TABLETOP SOCCER 16. Attach the net supports (F) and goal nets (Q) over the goals. redril the screw hole, then insert the screws through holes inthe cloth mesh before fastening the supports tothe ends. Then remove the goal nets prior to finishing (see “Staining and Finishing” below). STAINING AND FINISHING Woodworker's Tip: Though you may be tempted to cut short your sanding, preparation aid application, don’t do it These ‘tasks are very important ips in obtaining a bigh-quaity finish, ememiber, itis the finish, just as much asthe fit and smoothness (of the parts that will have great bearing on bow peopl judge your ‘craftsmazship. To ensure an excellent result, fllow the steps listed ‘elon and aso the instructions the finish manufacturer puis on tts products FINISHING TIPS * Use scrap of wood fo et the stuns and finishes you are planning to use. On the back of the scrap, mar the stain/insh combination andthe rpe of wood. Allow al samples to dry thoroughly before ‘making your final finish selection. Save your samples for quick ref erence on future projets, All stains and finishes must be allowed to dry thoroughly between coats. Remember that dying times can vary due to humidity and over eimatc conditions. 1 get addtional surface protection, ater Hnishing apply wo or three coat of Minwax® Piste Wax Bul each coat wth clean, st her bras; fer the ast wax application and bing, rub all surfaces with clean, lint-free coh Tou have some live stan or fais, wipe the can rim that stan o finish inte rim won't dry out and prevent the lid fom forming tight sel + Brushes used for o-based finishes must be cleaned with mineral spins; for waterbased products, suchas Minwax* Water Based Sain and Minwax*Polynlic® Protective Finish, clean brushes with ‘warm water and soap. 17. For this projec, you have the option of fnish-sanding and applying stain and finish to some pieces before theyre assembled. ‘Whenever you do the sandiag, use pad sander and withthe-gain ‘sanding strokes to remove any marks or scratches that may have ‘occurred during assembly. Sart with 120-grit paper and finish with 220-arit. Dust off the piece and wipe it carefully with a cloth lightly dampened with water. Recommended Finish 18, Apply Minwvax*Pre-Siain Water-Based Wood Conditioner, follow ing the directions onthe can. After | to 5 mines, wipe ff all excess conditioner using clean, in-free cloth. Wait 15 to 30 mimites and then use fine-grade paper sand off any "whiskers" raised by the conditioner. Proceed to the staining within 2 hours. 19, Do the taining in two steps, stating on the interior surfaces and then moving tothe exterior surfaces. Apply the Minwax® Water-Based ‘Wood Sian you've chosen tothe interior surfaces using ether a cloth ‘ora nylon/polyester brush. allow stan to penetrate no longer than 5 minutes. While stan is sill wet, wipe off all excess with a clean ‘loth thar’ been lighly dampened with stan, Allow the piece to dry for 2 hours before applying a second coat, if desire. Allow the piece to dry overnight before applying the clear finish Woodworker's Tip: Minwae* Water-Based Wood Stain is available in sx factory (wood-tone) colors, a White Wash Pickling Stain and 60 custom colors. This means thal you are not limited to just wood colors (ine, oak, walnut, et). We chose the colors to replicate the look of a soccer stadium, but jou can actually pick and apply your fevorte “team” or school colors. For this reason, look overall of ‘the Minteax* color charts before making your final selection 20. Apply Minwax”Polyeic® Protective Finish folowing te drec- tons on the can. Str the can content thoroughly Before tating and periodically repeat te stirring during your work session, 21, Working a small area ata time to maintain a wet edge, apply the frst coat. Work quickly and make the final strokes in each newly finished section using wih-he-gran brushsrokes. 22 allow the finish to dry a minimum of 2 hours. Then sand light with 220-grit sandpaper wrapped around a soft backup block. Thoroughly dust off and wipe all surfaces wih a cloth lighily dampened with water 23, Repeat steps 20, 21 and 22 to apply the second coat 24, Repeat the above steps o apply third and inal coat of rowctve inish Alternate Finish 25. Do the staining in two steps, starting on the interior surfaces and then moving o the exterior surfaces. Apply the Minvax® Wood Finish you've chosen tothe interior surfaces using a clean, line-free cloth Allow the stain wo set for about 1015 minutes then wipe off any remaining excess Repeat forthe exterior surfaces. low the iin to dry for 24 hours before applying the finish Woodworker's Tip: When wiping off stain, make certain that your ls wipe wit the cloth goes with the grain ofthe wood. This way, any stain you might miss during wipe-off will be visually minimized by the wood grain 26 Apply Minwax® Fas Drying Polyurethane follving the directions ‘on the can, Use a good quality natural bristle brush intended for use vith polyurethane. Allow the fist oat to dry overnight 227. ‘The nextday, sand all surfaces lghly with 220-t paper using ‘ih-te-grain strokes. Dust off and wipe all surfaces witha cloth lighly dampened with mineral sir. Apply a second coat of polyurethane and set the pice aside to cure overnight, 28, The following day, sand all surfaces lightly with 220-grt paper. Dust off and wipe the piece wih a cloth lightly dampened with min- eral spirits and apply the third and final coat of polyurethane.[cen earns rR TI RR soc 29, er the staining and finishing is done, and the piece has cured for several day, screw the rubber fet tothe bottom edges of the sides, reattach the gol nes, and hammer the hand grips ono the plaver/goaie rods. Wrap electrical tap around any dowels tat ned it {otighten te grips Sle the plaergoali ods in place, and you're ne. Let the games begin PRODUCT SAFETY For your safery and the say of those you work wth, always rea the salty warnings, which manufacturers print on their labels, and fallow them to the ltr. Typical sefey advice and instructions wil contin {information suchas te foloing: DANGER! MINERAL-BASED PRODUCTS ARE HARMFUL OR [FATAL IP SWALLOWED. SKIN IRRITANT. COMBUSTIBLE. KEEP ‘OUT OF REACH OF CHILDREN. DANGER: Coniins mineral spits. Harmful or fatal if swallowed Do not take internally. Skin irritant. ‘Avoid contact with skin and eyes. Wear ruber gloves and safety glasses when handing, Combustible. Do not use or store near hes, spars, flame or other souce of ignition. Case container afer each use void inhalation and we only with adequate venation. I using indoors, open all windows and doors to make sure there is fresh ait ‘movement Ifyou experience lightheadedness, dzsness or headaches, increase fresh air movemeat or leave the area. Reports have associated repeated and prolonged occupational overexposure to solvent with permanent bran and nervous system damage. Intentional misuse by deliberately concentrating and inhaling the Contents may be harm or fatal FIRST AID: If swallowed: Do not induce vomiting, Cal physician ‘immediately FOR SKIN CONTACT: Wash thoroughly with soap and water If {tation persis, get medial tention. [FOR BYE CONTACE IMMEDIATELY lsh ees thoroughly with water, then remove any contact leases, Continue to sh eyes with wate for at least 15 minutes. If ivitation persists, get medical attention If AFFECTED BY INHALATION: Immediately remove o fresh ai -fsympioms persis, cll pysician, ‘When using Minwax* Polyerylic® Protective Finish: ‘VAPOR HARMFUL. Use oni with adequate ventilation, To avoid overexposure, open windows and doors or use other means 0 ensure fresh air entry during pplication and drying. If you exper cence eye watering, headacies or dzanes, increase fresh ar supply or wear respiratory protecion (NIOSIVMSHATC23C or equivalent) cor leave the area, Avoid contact with ees and skin. Wash hands after using Keep container closed wien notin use. Do not ransfer contents to other containers for storage. DO NOT TAKE INTERNALLY. [FIRST AID. Incase of eye contac, fash thoroughly with large amounts ‘of water for 15 minutes and get medical attention. For skin contac, swash thoroughly with soap and water. In case of respiratory dif ‘uly, provide fresh air and call physician, If swallowed, get medical attention immediatly. DELAYED EFFECTS FROM LONG-TERM. OCCUPATIONAL OVEREXPOSURE. ‘Contains solvent that can cause permanent bran aud nerous tem damage, Inetional misuse by deliberately concentatng and inhaling the contents may be harmful oft SAFE DISPOSAL OF RAGS AND WASTE. Please be mindful of the safe way to dispose of rags and other waste. Rags, steal wool and other waste products Soaked with ol finishes oF solvents may spontaneously catch ire ifimpropery discarded, lace rags, sel wool and other wast immediatly after use ina watered ‘metal container. Tightly seal and dispose of the waste materials in accordance with local trash remoralreglations. Be sure to keep the waste ot of each of children, "This project adapted with permission from American Woodieorker maguzine, Home Services Publications, Ine, an afliliate of Reader's Digest Association, nc, Suite 700, 2915 ‘Commers Drive, Eagan, MN 55121. © Copyright 1997, All Rights Reserved, For subscriptions call toll-free: 1-800-666-3111. AUBINCCOVTINUED - WOODORKS.INTERMADIATE PROC 2002-2003, TABLETOP sOcOER FIG A. TABLETOP SOCCER ASSEMBLY . cee ges VAY DEEP XM" i 6:12" —r}a—5'—+} AABBETS AND GROOVES GoALIE-D HANDLEBAR, (ReaD) RP stop \ (@REQD) BIRCH ROD-@ WALNUT ROD-H. (4REQD) ASE 1.30" @NeT@REGD) NETSUPPORT B. END VIEW ‘. 1-16-01A. BIRCH RUBBER FEET (GRECO-SPER SDA) ¢ SOCCER BALL Noe x 1-16" DAYWALL SCREW; 38"-DIA, WOOD PLUG (2OFEACHREGD) ALTERNATE, POSITIONS ON EACH SIDE gs 4 . No.8 x94 BRASS: fetes ny FLATHEAD SCREW (12 READ) WUEBNRoe 6(CONTINUED - WOODWORKS:INTERMEDUITE PROJECT 2002-2003 TABLETOP SOCCER FIG B. CUTTING THE WEDGE FIG C. THE ROUTING JIG FOR THE ROUTING JIG —— ABE