Kansas City Art Institute: Picnic Table
A Step-by-Step Project Journal of Joe's Design, Fabrication and Installation
Kansas City Art Institute Picnic Table: Cutting the Aluminum
I had a template cut out on the cnc router and went about cutting the thick gauge aluminum square tubing to fit the pattern.
Kansas City Art Institute Picnic Table: Heavy Gauge Steel Bracing
Here is a good view of the heavy gauge steel bracing that slides in the aluminum structure prior to welding. The reason we did this was not because the aluminum tubing wasn’t strong enough rather it was because the welded aluminum joints once ground smooth would be susceptible to cracking. The steel takes the stress off of these welds.
Kansas City Art Institute Picnic Table: Steel Bracing Slides
You can see how the steel bracing slides in the tubing. A really snug fit but not to snug was critical here.
Kansas City Art Institute Picnic Table: Joints
Here is a close up of a typical joint.
Kansas City Art Institute Picnic Table: Complete Assembly, Ready for Welding
Viola, here is a complete assembly ready for welding.
Kansas City Art Institute Picnic Table: Assembled Template
Once I had one of these assemblies welded together I used it as a template to align the remaining two.
Kansas City Art Institute Picnic Table: Aluminum TIG Weld
A close up of a typical aluminum TIG weld.
Kansas City Art Institute Picnic Table: Welding Exposed Areas
The holes in the top of all of the exposed tubes had to be welded shut to prevent water from entering the assembly. This was a pain.
Kansas City Art Institute Picnic Table: Complete Assembly
A complete assembly after welding, grinding and sanding. Pretty!
Kansas City Art Institute Picnic Table: Comprised Pieces
Ok flash forward. Essentially the rest of this piece is comprised of six frames, two of which you can see in this pic bolted to the three leg assemblies.
Kansas City Art Institute Picnic Table: Bolted Connection
Here is a shot of that bolted connection. Notice the tabs that are for mounting the stone top.
Kansas City Art Institute Picnic Table: Additional Framing
Now we have added the additional four frames where the seat platforms will rest. This assembly design makes this table a snap to take apart.
Kansas City Art Institute Picnic Table: Configuring Assembly
You can see in this pic where we use dots to denote that these parts assemble in this configuration.
Kansas City Art Institute Picnic Table: Seat Pan Installation
The seat pans have been installed.
Kansas City Art Institute Picnic Table: Countersink and Threading
There were quite a few of these flush machine screws to countersink and thread.
Kansas City Art Institute Picnic Table: Transporting to Paint
Ship it out to paint! Notice how compact it is when broken down.
Kansas City Art Institute Picnic Table: Awaiting Paint Application
Here are all of the parts except for the seat pans sitting on the dock at the painter.
Kansas City Art Institute Picnic Table: Marble Installation
Black beauty. Here is the table at Carthage marble for the installation of the top.