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Cutting the Rabbet for the Glass Table Top
Easing the Edges of the Panels

Easing the Edges of the Panels

(c) 2007 Chris Baylor licensed to About.com, Inc.
We're getting close to assembly time. However, there are still a few details that need to be finished. One of those details is cutting the rabbet to accommodate the beveled glass table top.

This can be done a number of ways. Probably the easiest would be to use a rabbeting bit with a ball-bearing tip to cut the rabbet. However, this poses a problem, as you wouldn't be able to cut the acute 45-degree inner angle on one corner of the table top.

A better way to cut this rabbet is to set up your router with a 1/2" straight-cutting bit and a collar. Using a few straight sections of 1x6 or 1x8 as a guide clamped into place on the table top, you can easily route out the entire rabbet with rounded edges perfectly. Be patient and be sure to keep the base of the router firmly against the template, cutting out a rabbet that is 3/8" wide and 1/4" deep all the way around the inside of each of the two table top sections.

TIP: To avoid cutting the wrong sides of one of the two table top sections, it would be a good idea to lay the two sections out on your shop table in their final positions and mark the sides to be cut before you begin cutting the rabbet. Cutting the wrong side of one of the two table top pieces would be a frustrating mistake.

Before we can sand or assemble the piece, we should ease the top edges of each of the shelves and table tops using a 1/4" roundover bit on the router table. Be certain that you do NOT round over the edges along the 45-degree angles that are to be joined together to form the table top or shelves in the next step. Only the outer, top edges of the table top and bottom shelf should be rounded over. However, if you are using the optional middle shelf, you can round over the top and bottom outside edges on this shelf.
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