1 empty entrée tray
2 pieces of MDF(medium density fiberboard) ¾” x 7.5” x 10”
4 small brass nails
2 pieces of felt cut to fit tray sections
Wood glue, walnut stain, and amber shellac
Sandpaper (power sander if you have)
4 wood clamps or heavy weight
Cut two pieces of ¾” MDF to 7.5” x 10”
Lay out pattern on MDF pieces as shown in attached drawing, this is done by centering the entrée tray upside down on one pieces of MDF. Trace around the tray, then measure in ¼” from traced line at points A,B,C,D,E,F,G, and H as on drawing, then connect the points using the edge of the tray. To form the rounded edges make dots by hand and then connect dots. This forms the inside pattern to be cut out with saber saw.
Lay out the corners of the MDF by making a mark 2 “ from each corn and connect the points using the rounded corner of the tray.
Drill a hole next to the inside pattern and cut out the inner area with saber saw.
Use first piece to mark the cut out on the second MDF piece.
Cut the rounded corners on both MDF pieces.
Glue the 2 MDF pieces together and clamp or place weight on them to clamp.
Sand the new single piece until smooth and edges are rounded off on the top side of the piece.
Stain the MDF piece let dry, shellac the piece(or what ever finish you desire)
Fit and cut out pieces of felt and glue into bottom of tray sections
Place tray into cut out area of MDF piece and attach with 4 brass nails.
Many versions of this can be made with many different tray shapes and sizes, so go ahead and experiment and have fun! Email us and let us know what you come up with.