Need project advice: Ikea Malm occasional table

Hi there -

I'm looking for a good modern console and this is the one:

http://www.ikea.com/us/en/catalog/products/80196480/#/20209999

(Sorry I can't figure out how to attach a photo, so I just included the Ikea product page.)

So 2 questions: Can anyone suggest wood to use? MDF? A hollow core door? It will be painted and from the picture I'm guessing it's about 1.5-2" thick.

The dimensions are:
Width: 75 1/4 "
Depth: 14 1/8 "
Height: 28 7/8 "

Also, should the joints be made with pocket holes and screws or just finish nails w/ glue?

Thanks for your help!

claydowling

Sun, 01/29/2012 - 07:37

It's going to be hard to make that with a joint that will hold well. If I were going to build it I'd use a pine 2x12 and joint the legs with finger joints or dovetails. Alternately you could use a series of sturdy dowel tenons, something in the 1" range. Just be warned that most dowels sold in home centers are rather randomly sized.

Lady Goats

Sun, 01/29/2012 - 08:14

I'm with Clay, I'd probably do box joints for this... I would probably put some corner brackets on the inside (you could always rout out space for them so they're inset and a lot less noticeable), too. And, again, I'm with Clay on the would use 2xs. You could probably get away with a a few 2x6s to get closer to the dimensions of that table (which could use some pocket holes to keep them together). If you want to go the easy route and put this together with pocket holes or (and I wouldn't recommend this) glue and finish nails, you definitely need to add additional reinforcement. Like... a few of these on each side http://www.lowes.com/ProductDisplay?partNumber=67407-1277-MP121BC&langI…

claydowling

Sat, 02/18/2012 - 20:55

I saw this in the store and I have some more ideas about how to build it.

The actual table is made with honeycomb construction, and based on the weight I'd say they used 1/4" plywood for the walls and the internal ribs, possibly with a fiberglass wrapper. I was not impressed with the joint between the top and the legs. It was clearly bolted on and felt like it was going to fall apart within a year (a common problem with most Ikea furniture, which looks and feels very poorly made).

If I were going to build this as a console table that can slide over a bed, as the original Ikea product is, I would keep the honeycomb structure, but I would build some sockets into the legs and the top to accept some wicked long tenons, and I would secure them with glue rather than a metal fastener.

This is actually pretty simple construction to do, if you have the tools. But it's time consuming unless you have a shop set up for this kind of work. Start by using 1/2" plywood. Baltic birch or a cabinet grade domestic plywood would be recommended. Don't use the cheap junk they sell at the home center. This 1/2" product is heavier than what Ikea uses, but a honeycomb made from it will be easier to handle in the home shop.

You might be able to build this with a circular saw and a cutting guide, but your life will be made easier if you use a table saw to get more accurate cuts. Downside is that $500 is about the least you can spend for a good table saw. You also can't use the cheap blades they sell at the home center. Those are all thin-kerf blades, which wobble and don't leave a good glue edge. I recently had to spend for the good blades, at about $65 each (and I need one more). Completely worth the money, but hard to convince yourself of it until you see the cheap blades producing scraps instead of usable product.

sognoinunastella

Sat, 06/30/2012 - 16:55

I was just going on this forum to ask this same question. I want to make the ikea occasional table, it's way to expensive at ikea and it's made out of particle wood! What a rip off.

May I ask, what if a honeycomb construction?

I was thinking of going to home depot and buying 2x12 boards and having the crew at HD cut them to size for me.

Why wouldn't a pocket hole work? would the table be too unstable?

thank you for all the help!

claydowling

Sun, 07/01/2012 - 04:50

You can google honeycomb construction and get some good info. Fine woodworking had the best last I looked.

A home depot employee talked about why you shouldn't have them make your cuts in another thread. Basically the saws are abused and out of square and you have no real hope for accurate or useful cuts.

The more substantial joinery is because of the way the table top overhangs from the legs. A strong joint is mandatory.

sognoinunastella

Mon, 07/02/2012 - 16:05

I sent some time looking for honeycomb construction and it actually sounds awesome. But i don't think I have those skills (just yet)....

maybe using box joints? or mortise and tenon joint?

I don't know how to achieve either.... but i'm sure it's possible!

Thank you for all the help!

claydowling

Mon, 07/09/2012 - 18:44

The skill level for honeycomb construction is probably within your ability. If you buy 1x3 that can make the interior structure for the table. You can use a Japanese pull saw to make nice accurate cuts for the ribs. The pull saws at Lowes are inexpensive but can do very good work. That's the hard part, and it's all within your capability.

The skins, you cut those to be slightly oversized with a circular saw, and then use a router with a trim bit to get them to final size. The router is slightly expensive, but worth having. Once you have one you'll find lots of uses for it.