Table-Bracket Replacement

Do you have a broken bracket on a favorite old table? Follow these steps to make a replacement bracket that looks just like the original.
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Materials and Tools:

scroll saw (available for rental from home centers)
clean towel
file
paint brush
hammer
large and small nail sets
pen refill
drill bit
hacksaw blade
drill
120-grit sandpaper
rubber gloves
safety glasses
wood glue
wood stain
brads
scrap of cabinet-grade plywood

Steps:

1. Remove a bracket from the table to use as a template. Saw through the nails holding the bracket using a hacksaw blade.

2. Place the old bracket on a piece of cabinet-grade plywood and trace around it using a pen refill.

3. Cut along the outside line using a scroll saw. Be sure to wear safety glasses when working with power tools.

4. To cut away inside areas, drill a hole through the area to be cut away. Make a hole large enough to fit the scroll-saw blade through. Remove the blade and insert it through the hole. Reattach it and make your cut.

5. Continue cutting until you have a duplicate of the original bracket.

6. Use a small file and 120-grit sandpaper to smooth the edges. Apply stain to match the table using a small brush and towel. Do not stain the edges where you'll attach the bracket. Stain and glue don't work well together.

7. After the stain dries, pre-drill pilot holes for the nails in the ends of the bracket.

8. Dab some wood glue on the surfaces where the bracket attaches to the table, and position the bracket.

9. Position a small nail in one of the pilot holes and drive it in partially using a large nail set and hammer. Finish driving in the nail below the surface using a smaller nail set. Repeat for the other side of the bracket.

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