Notes from IPG meeting #1.

Session 1 - 04/27/2019

Demilune Table Project - Topics of discussion

Design process - see handout

• Sketches help get the process started
• Console tables are small, approximately 28 inch to 34 inch max height
• Scale models are helpful
  • Use plywood, poplar, hot glue
• Full size cardboard mockups are very useful
• Consider elipse vs. round shape
  • Elipse templates very useful
• Joinery drawings

Building a mold for the bent lamination table apron

• 1/4" MDF used for the templates 
  • Baltic birch plywood is an acceptable alternative
• Elipse has two axes (radii)
  • 1/2 x 21" major axis
  • 1/2 x 13" minor axis
• French curve templates help with the drawing and shaping the template
  • Amana router bit #47096 (ToolsToday.com) used for pattern making
    • blades are slightly angled for a shear cut, with upper and lower bearings
• Template is used to shape each identical layer of 3/4" MDF at the router table
  • completed mold uses multiple layers of 3/4" MDF, sufficient to accommodate dimensions of the bent lamination plus "landing zones" beyond each end of the laminated apron final dimensions

Resaw multiple ~3/16" slices of walnut stock at bandsaw for the bent lamination

• bandsaw marks cleaned up running each slice through the thickness planer using a sled to an ~1/8” thickness 

Bent lamination glue up of each layer using Unibond 800

• two ingredients of Unibond 800 glue mixed together
• glue applied between each layer 
  • a 3" paint roller used to apply glue to
  • each walnut layer stacked onto the previous layer
• After final walnut layer glued to previous layers the multi-layered walnut is quickly clamped to the form, beginning at the center line and working out toward each landing zone
  • Clamps applied every few inches, bending the multiple layers of walnut  around the mold

End of IPG session #1.