How to build a Folding Montessori tower and table — 15 5/8" × 15 5/8" × 35 3/8"

Cut list

Step by step

1. Shape the side openings

   Form the circular side openings on fully supported blanks.

   • Support each side on sacrificial blocks outside the intended opening.
   • Clamp each side to the bench with the cutting path clear.
   • Mark the opening centers from the front and bottom edges.
   • Drill a starter hole inside each waste circle.
   • Guide the jigsaw around each marked circle.

2. Round the access bar

   Shape the access bar to the marked rounded section with the sander.

   • Mark a centered 1 1/4" circle on each end of the bar.
   • Clamp the bar in a sacrificial cradle above the bench.
   • Sand shallow flats toward the marked circles with coarse abrasive.
   • Rotate the bar in the cradle between flats.
   • Blend the flats without reducing the marked diameter.

3. Drill the side latches

   Drill the positive-lock splints and their matching side holes.

   • Align each upper side with its matching lower side on a flat bench.
   • Center each 6" splint over the seam, halfway along the side depth.
   • Clamp the splints and sides over sacrificial backing.
   • Mark both bolt centers 2" above and below the seam.
   • Drill the matching holes with a 9/32" bit.

4. Smooth the exposed edges

   Sand the blanks and openings before assembly.

   • Sand the exposed faces with 120-grit abrasive.
   • Ease exposed edges by about 1/16".
   • Smooth the opening edges with folded abrasive.
   • Finish the exposed surfaces with 180-grit abrasive.

5. Assemble the lower frame

   Fasten the fixed deck, access step and lower stretchers between the lower sides.

   • Space the inner side faces 12 5/8" apart.
   • Clamp the fixed deck flush with the side tops.
   • Clamp the step with its top 8" above the floor.
   • Position the rear rail flush with the back and top edges.
   • Position the front stretcher 1" above the floor.
   • Drive the 2" screws through clearance holes and pilot holes.

6. Assemble the upper frame

   Fasten the reversible deck, rear rails and rounded bar between the upper sides.

   • Space the upper inner faces 12 5/8" apart.
   • Clamp the reversible deck flush with the bottom edges.
   • Clamp the lower rear rail flush with the back and bottom edges.
   • Clamp the top rear rail flush with the back and top edges.
   • Center the rounded bar 1 3/4" from the front and 1 1/2" below the top.
   • Drive the 2" screws through clearance holes and pilot holes.

7. Install the locking hinges

   Join the aligned assemblies with two rear hinges that positively lock at full fold.

   • Seat the upper frame on the lower frame with all seam faces touching.
   • Clamp the assemblies together on a level surface.
   • Center the hinge pins at the seam on the rear face.
   • Space the hinge centers 3" inward from each rail end.
   • Drill shallow pilots through the six holes of each hinge.
   • Fasten both hinges with the 5/8" pan-head screws.

8. Fit the upright latches

   Secure both sides with the removable through-bolted timber latches.

   • Place each timber latch against the outside of its matching side.
   • Insert a 2" bolt with a washer through each latch hole.
   • Fit an inner washer and wing nut to every bolt.
   • Tighten all 4 wing nuts against the washers.
   • Confirm that both upper bolts pass completely through their matching sides.

9. Check both configurations

   Perform an unloaded, two-adult conversion check before finishing or any use.

   • Support the upper assembly with a second adult.
   • Remove both upper latch bolts and their loose fittings.
   • Swing both timber latches downward around their lower bolts.
   • Rotate the upper assembly rearward through 180 degrees.
   • Engage both retained hinge locks in the fully folded position.
   • Check the tabletop, floor contact and all moving clearances.

10. Finish and review

    Apply the finish and obtain a child-use safety review before putting the piece into service.

    • Remove sanding dust from all surfaces.
    • Apply the green water-based finish according to its label.
    • Keep finish off the hinges, threads and bearing faces.
    • Allow the full labeled cure time.
    • Recheck every fastener and lock after curing.
    • Arrange a competent review of stability, guarding and entrapment before child use.