Step 2: Screw the Form Together

Mark Powers fastens pieces for a hypertufa table with a drill/driver
Photo: Wendell T. Webber
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Place two reinforcing blocks flush with the ends of each long side. Secure them by driving 1 inch screws through the blocks and into the long sides. Sandwich the long sides between the short sides, with the blocks facing outward, as shown; the ends of the short sides extend past the blocks so that the form can be pulled apart easily when the tabletop has cured. Mark locations for pilot holes on the tops of the short sides and the edges of the blocks. Drill 1/16-inch pilot holes through these marks. Secure the form by driving 1 inch screws through the pilot holes.

Tip: You can make the tabletop longer or wider than ours, but doing so may require adding extra stretchers or crosspieces to the base for support.
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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