How to Make a Coaster Holder

QUANTITY	LETTER	NAME	SIZE	MATERIAL
1	A	Base	5/8" x 5 5/8" x 5 5/8"	Pine
4	B	Dowels	1/4" Dia. x 3 3/8"	Pine
4	C	Adhesive Surface Savers	1/4" Diameter	Felt
WOOD SPECIES
Ponderosa Pine

B. Cutting Procedures:

1. Use a planer to plane base (A) to 5/8" thickness.
2. Use a table saw to rip base (A) to 5 1/16" width.
3. Use a radial arm saw to cut base (A) to 5 1/16" length.
4. Draw a 9/16" radius at each corner.
5. Cut each corner radius with a jig saw or a band saw.
6. Use a belt sander to sand the sides of base (A).
7. Use a spindle sander to sand the corner radii of base (A).
8. Use a drill press and a 1/4" Foerstner Bit to drill four holes through the corners of base (A) with centers 3/8" in from each side.
9. Use a band saw to cut four 1/4" dowels to 3 3/8" in length.

1. Hand sand base (A) with 80 grit sandpaper.
2. Hand sand base (A) with 120 grit sandpaper.
3. Hand sand base (A) and dowels (B) with 220 grit sandpaper.
4. Slightly round all edges of base (A) and top ends of dowel (B) with 220 grit sandpaper.

1. Place a small amount of wood glue in each hole.
2. Use a wooden mallet to tap each dowel (B) through the base (A) to extend 1/8" beyond the bottom.
3. Immediately clean excess glue off the base and the exposed portion of the dowels with a wet paper towel.
4. Allow glue to dry 24 hours.

1. Fill any cracks or holes with wood dough.
2. Allow wood dough to dry for 2 hours and then sand flush with 220 grit sandpaper.
3. If stain is desired, apply with a brush and allow to penetrate for 5-10 minutes, and then remove with a clean rag.
4. Allow stain to dry for 6 hours.
5. Apply a clear coat of Varathane, Polyurethane, etc. using a bristle brush. Allow to dry for 24 hours.
6. Lightly sand with 220 grit sandpaper.
7. Clean all dust with a tack rag.
8. Apply a second coat of clear finish and allow to dry for 24 hours.
9. Attach adhesive surface savers (C) to the bottom of each dowel.
Note: This coaster holder is designed to hold eight 4 1/4" square coasters.