
Generally, if you require a piece of furniture you go to a store or two, choose a design you like on a budget you can afford and purchase the item.
As a builder I can’t see myself constructing my own sofa or chairs, but items like bed frames, tables and desks are all things I’ve had a go at, with successful results. Making an item from scratch no matter how simple gives a feeling of achievement you don’t get from store-bought furniture, and if you’ve designed it yourself, even better.
Here’s a desk you might like to have a go at and because the materials and method are simple, maybe change it up and design your own coffee table, dining table, side table or stool. Maybe even a bar leaner.
Tools:
- Ruler
- Tape measure
- Pencil
- Drill
- Impact driver – screwdriver
- 28mm Speedbone drill bit / 3mm drill bit
- Sand paper
- Allen key
- Craft knife
- 45mm screws / 8 gauge
- Super coarse plastic
Materials:
- 24mm Plywood (I’ve used birch)
- 1 piece at 1600mm long x 700mm wide
- 2 pieces at 640mm long x 70mm wide
- 20mm Galvanised water pipe
- 4 pieces at 660mm long
- 2 pieces at 540mm long
- 4 x 20mm x 90 degree quick clamp elbows
I chose birch ply for the desktop as it is strong and stable, the colour is light but can be stained any colour and is relatively easy to finish with oil or polyurethane.
I have the equipment to cut the plywood accurately but suggest getting a joiner to cut your plywood components accurately. With the desktop being 700mm wide I have a 2400mm x 500mm off cut which I can use for another project. It may become shelves or a coffee table, but because of the price it will not go to waste.
I had the galvanised pipe cut by the merchant (Steel and Tube) at a very low cost and it made it easier to transport.
Important to note:
Although the pipe has a nominated size of 20mm, this is the internal diameter of the pipe and the external diameter is 27mm.
Step 1 - Legs
The two pieces of ply (640mm x 70mm) are the base for the legs. Each of these pieces need a 28mm hole drilled through at each end. Mark 35mm in from the side and 35mm in from the end.

Drill a 28mm hole right through the ply.

It would be ideal to drill a 27mm hole, as the pipe diameter would be a perfect fit, but speedbore drill bits don’t come at that size. To make the leg fit tightly, a shim of super coarse plastic is just the right size. Cut a strip of super coarse.

Place in the hole.
Fit 660mm length of pipe into the pipe hole.
Then twist clockwise until the pipe is flush with the other side of the ply.
Repeat for both pieces of ply and all four lengths of the 660mm pipe.
The quick clamp elbows have Allen key threaded grub screws, which clamp firmly to the pipe. Loosen all of the grub screws off so that the pipe can slide into the elbow.

Fit one elbow to each end of the two pieces of 540mm long pipe.

The measure between the two legs fitted to base ply should be 570mm centre to centre.
Fit the other elbow to the end of 540mm pipe and ensure it is 570mm between the two elbow centres before tightening.

Fit the pipe with elbows to the legs and measure to make sure both sides are even before tightening with Allen key.

The measure from the ply to the bottom of the elbow should be 610mm.

Trim off excess super coarse plastic with a craft knife and the legs are ready to fit to the desktop

Step 2 - Fitting to desk top
Lay top on stools using drop sheets or soft cloths so as not to damage the top of desk.

Sit legs in approximate position and measure it from end and edges 30mm.

Face the grubscrews on the elbows to the inside.

Pre-drill 3mm holes at each end of the base ply, approximately 15mm in from edge.

Before fixing the leg to the top, check that the screws are not too long. A screw coming though the desktop is not a good look. 45mm screws are perfect so long as they are not over tightened.

Using an impact driver, or screwdriver, screw the base to the top through the predrilled hole.
Two screws at each end of the base are enough to hold firmly to the top.

Fit the other legs the same.

Turn the desk over and hand sand all of the edges and faces of ply with maximum 220 grit sandpaper.

Desk can be left natural by oiling with teak oil or polyurethane.
Note. The height of the desk is approximately 720mm. Desks and or tables are usually between 710mm and 760mm. If the top is thin, then the desk can be towards the lower height. A standard chair is 450mm to the top of the seat and the general rule of thumb is to have a 300mm gap between the top of the seat and the top of the desk. With adjustable office chairs, a comfortable work height can be achieved by the raising or lowering of the chair.
So try my desk and have a look at how Michelle dressed it up. You can make your own industrial style bespoke table or whatever you dream up. I’ve given you an idea and a method, make it your own.
Cheers,
Cocksy.
This article is intended as a general discussion only. BNZ recommends the recipient get independent advice. The views expressed are the writer’s own and do not necessarily represent those of BNZ or its related entities.



































































































