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

Fig.1 White Board 
Instructions

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
Scraper  
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:

• Part 1 of 2 - Board Preparation
• Part 2 of 2 - Inside Board Replaced

How to Seal a Coffee Tray:

• Part 1 of 6 - Washing
• Part 2 of 6 - Oil Seal Coat
• Part 3 of 6 - Apply Polyurethane to Tray Bottom
• Part 4 of 6 - Sealing The Top
• Part 5 of 6 - Cleaning The Tool
• Part 6 of 6 - The Finish Product

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