Overview

illustration of how to build a hypertufa table
Illustration: Gregory Nemec
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CUT LIST:

You can use the cut list below or Download a cut list to build this hypertufa table here.

1x2 legs: 4 @ 14 inches
1x2 upper support blocks: 4 @ 11 inches
1x2 lower support blocks: 4 @ 3 inches
1x4 form frame, short sides (scrap): 2 @ 28 inches
1x4 form frame, long sides (scrap): 2 @ 30 inches
1x4 reinforcement blocks: 4 @ 3 inches
¾-inch rigid-foam insulation: 1@ 20 by 30 inches
¾-inch rigid-foam insulation: 2 @ 7 by 14 inches
1x4 lower crosspieces: 2 @ 10 inches
1x4 upper crosspieces: 2 @ 21 inches*
1x4 lower stretcher: 1 @ 31 inches*
1x4 upper stretchers 2 @ 31 inches*

*After they're cut to length, miter the ends of the upper crosspieces and all three stretchers at opposing 45-degree angles, and clip 1 inch off the long points of the ends. For each piece, the longer edge will be the top edge.

Notch cut instructions:

All notch cuts are ¾ inch wide and extend to half the width of the board, or 1¾ inches. Always measure the positions for the notches along the top (long) edge for each piece, no matter which edge the notches are cut on. See diagrams for positioning and sizing.

For each 1x4 lower crosspiece:
The notch should be centered on one edge of the board; the notched edge is the top edge and will face up during assembly.

For each 1x4 upper crosspiece:
Cut notches on the top (long) edge. Position the notches 3 inches from each end, measured along the top (long) edge. The notches will face up during assembly.

For the 1x4 lower stretcher:
Cut notches on the bottom (short) edge. Position the notches 4 inches from each end, measured along the top (long) edge. The notches will face down during assembly.

For each 1x4 upper stretcher:
Cut notches on the bottom (short) edge. Position the notches 3 inches from each end, measured along the top (long) edge. The notches will face down during assembly.

Project timeline:

Prep Day: Cut and assemble the form (Steps 1 through 5).
Saturday: Make the hypertufa mix and cast the tabletop
(Steps 6 through 10). Wait a few weeks for the tabletop to cure.
Sunday: Assemble the base and set the tabletop on it (Steps 11 through 18).
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    Tools List

    • miter saw
      miter saw
    • jigsaw
      jigsaw
    • drill
      drill/driver to assemble the form.
    • utility knife
      utility knife for cutting the foam.
    • aviation snip
      wire snips
    • mixing tub
      mixing tub to make the hypertufa mix.
    • masonry hoe
      hoe
    • Natural-bristle chip brush
      chip brush to spread petroleum jelly on the interior of the form before casting the tabletop.
    • finish hammer
      hammer
    • pneumatic finish nailer
      pneumatic nail gun

    Shopping List

    1. 1x4 scrap lumber for the form.

    2. cedar 1x4s for crosspieces and stretchers.

    3. cedar 1x2s for legs and support blocks.

    4. 1¼-inch and 2-inch deck screws

    5. perlite Get two bags.

    6. peat moss Get one large bag.

    7. portland cement Get a 47-pound bag.

    8. acrylic fortifier for the hypertufa mix, to prevent cracking. 9. ¾-inch rigid-foam insulation

    10. petroleum jelly or cooking spray to coat the interior of the form.

    11. ¼-inch hardware cloth

    12. plastic sheeting to cover the form while the tabletop cures.

    13. polyurethane glue, such as Gorilla Glue.

    14. 1-inch brad nails

    15. dust mask and protective gloves