DIY Aluminum Desk

Types

• Aluminum comes in a variety of forms and is appropriate for several different types of desks. Aluminum panels, which are available in standard sizes and are ready for cutting and drilling, can form traditional desk surfaces, sides and drawers. A portable desk can make use of a small aluminum panel and a vertical aluminum rod, allowing you to slide the desk in front of you while seated to use a computer or read a book while sitting on another piece of furniture. Lap desks can also be made from aluminum, specifically thin aluminum laminate that you can apply over wood or another surface.

Tools

• Working with aluminum requires some specialized tools, which you may need to borrow or rent depending on the scope of your project. If you plan to build a custom aluminum fame for your desk, you'll need a tungsten inert gas welder. A circular saw, table saw or drill press, with the right blade or bit, can cut through most types of aluminum. You'll also need metal files to smooth the rough edges and make your desk comfortable to work at.

Plans and Forms

• Most woodworking books, websites and catalogs offer plans for making your own wooden desks. These plans can serve as the basis for an aluminum desk. If you want to replicate an existing desk, measure each of its flat surfaces to convert it into a plan for your aluminum version. The plan you choose to work from will aid in determining how much aluminum to buy and how to proceed with the project.

Process

• Working with aluminum carries many of the same challenges as working with wood. Use a marker or awl to mark the surface where you plan to cut. If you select thick aluminum panels, lubricate your drill bits and saw blades as you work to ensure that they stay sharp and produce straight cuts. Stainless steel nuts and bolts will hold your aluminum desk together without altering its clean lines and industrial look. Filing all rough edges is the final step before finishing or sealing. To paint an aluminum desk, use 100-grit sandpaper to prepare the surface for best adhesion.