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
- Amana router bit #47096 (ToolsToday.com) used for pattern making
- 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.
Meeting Reports
Intermediate Projects Group