Wednesday, November 26, 2014

How to Replace Coffee Tray Damaged Bottom with White Hardboard - Part 2 of 2 - Inside Board Replaced

Fig.1 White Board 
By Gary Boutin

Supplies and Tools: 
Black + Decker Jig Saw 1/7 hp
Latex white Caulking
Loctite High-Performance Spray Adhesive 13.5 oz.
Parts Brush
Hand Gloves black
Husky X-Workhorse Workbench
Ryobi 18-Volt Power Caulk and Adhesive Gun
Spray Loctite Adhesive
Spring Clamps (2) 
Stanley Quick-Change Retractable Knife
White Hardboard Panel Board
File-Wood Flat Rasp 
Wood Chisel 2-inch  
Wood Jig Saw Blades
Wood Rasp Half Round

The coffee cup series was written in April 2014 showing how to treat a new hardwood tray into service and long lasting wear. The coffee tray was redone in October 2014 because the bottom board started to be removed by the coffee cups being stored after use. The project did not quite fail because it lasted six months and now being re-worked for future use.

This post shows the nineteen steps to replacing the bottom board with a new board whiteboard without destroying the existing wood coffee tray. This is the second part of this post.  

Step 1: Fig.1 shows the white hardboard instructions.
Step 2: Fig.2 shows the jig saws that will be used to cut the white hardboard.
Fig.2 Jig saws
Step 3: Fig.3 shows the jig saw blades that will cut the hardboard.
Fig.3 Jig saw blades
Step 4: Fig.4 shows a Black + Decker Jig Saw cutting the white hardboard.
Fig.4 First cut
Step 5: Fig.5 shows the first cut on the white hardboard. The thicker line is the newly cut line in between the jig saw.
Fig.5 Past the line
Step 6 Fig.6 shows the first cut is past the line so that when the other cut is done it wall fall into the Handyman's hands. Fig.4 shows the last cut of the white hardboard.
Fig.6 Last cut
Step 7: Fig.7 shows the alignment of the whiteboard into the coffee tray. A little tight on both sides, to little to use another saw. What to do?
Fig.7 First Placement
Step 8: Fig.8 shows the combination of flat rasp and half round wood file were used to trim the edges of the hardboard. 
Fig.8 Rasp Files
Step 9: Fig.9 shows the half round wood file filing off the hardboard edges.
Fig.9 Filing the edges
Step 10: Fig.10 shows a 2-inch Wood Chisel was used to scrape the bubbles from the bottom of the coffee tray.  
Fig.10 Wood Chisel 
Step 11: Fig.11 shows the use of a Parts Brush to remove any dust from the coffee tray.
Fig.11 Part Brush
Step 12: Fig.12 shows the Loctite High-Performance Spray Adhesive that will be used to adhere the white hardboard to the coffee tray.
Fig.12 Spray Adhesive
Step 13: Fig.13 the coffee tray is sprayed with adhesive and let dry for a few seconds.
Fig.13 Coffee Tray sprayed
Step 14: Fig.14 shows the backside of the white hardboard have been sprayed with the adhesive also do dry for a few seconds.
Fig.14 Hardboard sprayed
Step 15: Fig.15 the white hardboard panel board has been inserted inside of the coffee tray. Pushed down so the white board is attached to the backside of the coffee cup tray. Now let the adhesive dry.
Fig.15 Coffee Tray
Step 16: Fig.16 shows the coffee tray the edges needs to be sealed with white latex caulking. Insert the caulking into the (a manual caulking gun) or battery operated caulk gun.  

Fig.16 Ryobi Power Caulk/Adhesive Gun
Step 17: Fig.17 shows the white caulk on the edges of the coffee tray.  
Fig.17 Caulking applied
Step 18: Fig.18 shows a home sponge was used to remove the extra caulking on the edge of the coffee tray. This keeps it neat and better looking.
Fig.18 Sink sponge
Step 19: Fig.19 shows the job is done. This will fix the coffee tray and now we can have coffee and sugar confined to this area again.
Fig.19 Job done

How to Replace the Coffee Tray Damaged Bottom with White Hardboard:
How to Seal a Coffee Tray:

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Note: The DIY Advisor assumes no liability for omissions, errors or the outcome of any jobs. The reader must always exercise reasonable caution, follow current codes and regulations that may apply, and is urged to consult with a licensed contractor if in doubt about any steps on these posts. All names were changed to protect client's privacy. DIY Advisor. Reproduction of site content including photos without permission prohibited. All rights reserved. © Copyright 2011-

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