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Robust and practical, this small metal table is a precious auxiliary in the garden but also at home. Disadvantage, it rust! And when its tray is punctured, only one solution is needed to save it, the pure and simple replacement of it.

Text and photos C. Petitjean

Practical advice

● The cutting of the tray is done by shears, but it is possible to use a jigsaw with a fine-toothed blade. Hold the sheet so that it does not vibrate.
● A butane or propane torch, or even a simple soldering torch suffices (provided they sufficiently heat the sheet to allow it to work). The oxyacetylene model is not essential.

Found in an attic, this small folding table deserved to be restored. The square pedestals are much rarer than the rounds, and it would have been unfortunate to put it to the bulky. There are still such objects in flea markets, "garage sales" at Emmaus. In this case, the base is in good condition. The job is then to manufacture a formed sheet metal tray.

Remove the old tray

The original plate is a sheet metal plate held on its periphery by the folding of the metal, without other mechanical connection (rivets, welding...) with the support frame in flat iron. The attack by rust being deep, it is easy to separate them. sketched with an old screwdriver, the work is continued with flat chisel (or riflard, or brick chisel) in the healthier parts.
● The flat iron frame is mechanically etched at the grinder and then chemically treated with a passivator to neutralize inaccessible rust encrustations. When he is not flat, he is straightened with a hammer before receiving his new dressing.

Manufacturing

The replacement tray is drawn from an ordinary sheet of 10 / 10th mm thickness. Its dimensions are those of the frame, increased on each side by a margin of 15 mm to fold down the metal. The frame, secured to the base, is returned to the sheet to reflect its outline, using a felt.
● A second plot made at 15 mm around the previous one gives the location of the cut, then made to the curved shears. The shape of the rounded corners is sketched at the anvil with the breakdown of a postillon hammer: the hammered metal extends and hinges.

Setting up

The tray is placed on the base turned over, then carefully positioned and immobilized with clamps. A dropped edge is then made all around the support frame. The sheet worn red with a blowtorch is gradually folded by marrying well the upper edge. The corners require care and patience: shearing the edge of the edge makes it easier to fold but weakens the edge (see photo 6). The table is finally returned to beat the sheet under the frame.
● The base has received over the years multiple layers of paints. It is sanded with medium sandpaper, then thin, before receiving with the tray two coats of glycerophtalic gloss red Basque same. And finally, an antirust (Rustol) is added to the paint.

Separate tray and support frame

Separate tray and support frame

The tray of the pedestal, extremely corroded, separates easily from its support frame, integral with the base. Lift the sheet flap all the way around using a flat chisel.

Eliminate rust

Eliminate rust

To eliminate rust, use a small angle grinder, then neutralize the remains with a chemical rust remover. The frame, which will be heated later, can not be repainted in advance.

Cut out the sheet

Cut out the sheet

Repeat around the frame on a sheet of sheet metal 10 / 10th mm, then draw a new mark 15 mm around the first. Cut the sheet to the shear following this second contour.

Shaping the corners

Shaping the corners

The four corners must be shaped like a bowl. Hold the inclined plate on the anvil and hit the edge with repeated bursts to stretch the metal and prepare its folding.

Bridle and heat the sheet

Bridle and heat the sheet

Clamp the sheet sandwiched between the frame and a flat iron chute and hold the assembly with two vice grips. Warm red the overflow part over a length of a few centimeters.

Shaping the corners

Shaping the corners

The four corners must be shaped like a bowl. Hold the inclined plate on the anvil and hit the edge with repeated bursts to stretch the metal and prepare its folding.

Finish the border

Finish the border

Flip the tray on a flat surface. Finish the border by further folding the sheet, hammered on the underside of the frame. The border must be regular and the folds well marked.

Paint and protect

Paint and protect

To protect and decorate the metal, cover the entire pedestal table with two coats of glycerophthalic paint. If the paint does not include a rust inhibitor, add one.


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