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Jellyfish Table #4: Making The Oval

Blog entry by Blake posted 127 days ago 580 reads 0 times favorited 18 comments Add to Favorites Watch
« Part 3: Legs and Base Part 4 of Jellyfish Table series Part 5: Dying the top BLUE and spraying the lacquer »

THE OVAL

The apron for this table is going to be a bent-laminated oval:

I found a great tutorial on how to draw a simple oval on a website called In the Woodshop with Howard Ruttan. Here are some of the simple drawings on his page:

And here is mine:

MAKING THE FORM

So I cut it out with the jigsaw:

Then I used the first oval as a router template to cut its clone:

(I broke my favorite spiral router bit in the process)

The two MDF form halves were already stuck together with carpet tape. So I cleaned up the edges on the Oscillating belt sander:

The reason I have two MDF ovals is that I will need my form to be 3” tall. So here is the spacer I made out of a scrap of 2×4:

The clamps align the two ovals while I screw them to the 2×4 spacers:

3” Tall:

A sewing tape is a very handy measuring tool to have in a woodshop for measuring around ovals. Believe it or not the circumference of this oval is about 7 feet around.

PREPARING THE STOCK

So here is the 2”x5” x 9 ft piece of Mahogany that will become the oval. First I cut it to approximate length:

Then I jointed it (I love my full-sized jointer)...

Ripped it to a little more than 3” wide:

Re-sawed it into strips (I rolled my bandsaw outside to save the shop from a little dust)...

Planed them down to 1/8”...

And sanded them down to about 1/16”...

THE GLUE-UP

Here is my completed form, screwed to an MDF base which was first covered in plastic painter’s tarp. Then the sides of the oval were wrapped with plastic packing tape.

I didn’t take any photos during the actual glue-up for obvious reasons. It was a very stressful process, and didn’t go quite as planned, but came out fine in the end. I enlisted the help of my wife for an extra set of hands to help hold stuff and hand me clamps, etc. (Thanks Sweetheart!)

I originally thought I would use three “Pony” strap clamps to pull the strips in tight to the oval form. But it didn’t work quite as well as I had hoped so I ended up drilling holes in the top of the form and using bar clamps over the strap clamps. If I did it again I would just use the bar clamps.

This was the result:

In the end It came out fine. I knocked it loose from the form:

Ran the edges through my thickness sander, and cleaned the glue off the inside/outside surfaces with my Oscillating spindle sander (not pictured)...

ONE SOLID MAHOGANY OVAL…

...just a peak at all the components put together…

Total Project Time So Far: 40 Hours

-- Check out my new website! http://www.blakeweberwoodworking.com


18 comments so far

View Karson's profile (online now)

Karson

25271 posts in 1278 days


posted 127 days ago

Blake: The table looks great. The oval came out great nice job on the jig and the laminations.

I found a piece of wood in my shop last night and I thought of you and this table. I’ll have to get a picture to show you. It’s a natural edge circle maple burl. about 3’ in diam.

-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †

View majeagle1's profile

majeagle1

417 posts in 374 days


posted 127 days ago

I’ve been following along – wow, what a piece of art this is going to be. Can’t wait to see the completion.

Great job Blake…................and great instructions / tips !!!!!

-- Gene, Majestic Eagle Woodworks, http://majesticeagleww.etsy.com/, http://www.flickr.com/photos/majesticeagle/

View bfd's profile

bfd

413 posts in 684 days


posted 127 days ago

That moisture in the air is me drueling …unbelieveable! Blake I am coming to you with any future laminating questions. I am currious about the seam where the oval is complete I am assuming that the layers are staggered? I am not sure if you had enough clamps though LOL.

-- Brian, Folsom, CA http://www.brianfullerdesigns.com

View lew's profile

lew

4405 posts in 633 days


posted 127 days ago

dang,

bfd stole my clamps comment!

I would have never thought of using the thickness sander to finish the edges!

This table is going to be awesome!

View Blake's profile (online now)

Blake

2715 posts in 752 days


posted 127 days ago

Yes, thanks for reminding me. The seems in each layer are staggered.

-- Check out my new website! http://www.blakeweberwoodworking.com

View dlcarver's profile

dlcarver

258 posts in 608 days


posted 127 days ago

Fantastic Blake! I can’t imagine doing a job like that. WOW!!
Dave

-- Dave Leitem,Butler,Pa.,http://dlcarver.etsy.com

View Thos. Angle's profile

Thos. Angle

4015 posts in 840 days


posted 127 days ago

Very impressive, Blake. an excellent step by step tutorial as well. Well done!!!

-- Thos. Angle

View pommy's profile

pommy

892 posts in 569 days


posted 127 days ago

Blake the top is looking cool mate

Andy

-- cut it saw it scrap it

View Todd A. Clippinger's profile

Todd A. Clippinger

5588 posts in 977 days


posted 127 days ago

Awesome job!

-- Todd A. Clippinger, Montana, http://amcraftsman.com

View Beginningwoodworker's profile

Beginningwoodworker

3853 posts in 550 days


posted 127 days ago

The table looks great, Blake.

-- CJIII Future cabinetmaker

View patrick m's profile

patrick m

180 posts in 691 days


posted 127 days ago

JellyFish Go JellyFish ! Nice …. I love anything Nautical with Wood.
Repeat : Nice job clamping/jig

-- PJM.`·.¸¸.·´¯`·.¸¸.·´¯`·.¸ ><((((º> ""BY HAMMER AND HAND ALL ARTS DO STAND""1785-1974 nyc Semper Fi, Patrick M

View a1Jim's profile

a1Jim

15521 posts in 455 days


posted 124 days ago

great job

-- Jim from Heirloom Woodshop Southern Oregon

View Karson's profile (online now)

Karson

25271 posts in 1278 days


posted 123 days ago

Blake: I found the piece of wood in my shop again.

Here is the blog on it. It’s smaller than I thought. 30” high and 32” wide and about 2” thick on the flat spot. The thickness is not the same through the whole piece.

-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †

View blockhead's profile

blockhead

268 posts in 186 days


posted 122 days ago

Looking great Blake. Excellent job on the laminating. This is one beautiful piece. Can’t wait to see it completed.

-- Brad, Oregon- Wood, it's what's for dinner.

View Russel's profile

Russel

2030 posts in 817 days


posted 122 days ago

Your documentation skills are only outdone by your creativity and woodworking skills. The table will be fantastic and you’ll have a detailed story of how it was made. Very well done.

-- When you give someone a chance it may well be their last.

View Kent Shepherd's profile

Kent Shepherd

717 posts in 164 days


posted 85 days ago

What a craftsman!———-Thanks

-- Kent Shepherd * The goal is-----More Tools!

View Brad_Nailor's profile

Brad_Nailor

1192 posts in 835 days


posted 84 days ago

Blake this is looking very cool….I just cant help but think that when I look at the picture of the dry fit, the table looks like it might be a little unsteady. The size and mass of the tabletop, combined with the small diameter of the bearing surface (leg support, legs) and the tight diameter you put the legs in just seems to me from looking at the picture that one bump and that table is going to tip over. Maybe it is more stable in person, but from the pictures it looks like it might be a little tippy. Maybe you should have placed the legs a little farther out from the center…closer to the inner diameter of your oval apron?...Just an observation…..it’s looking like a high quality one of a kind piece!

-- David, South Windsor, CT "I love the smell of sawdust in the morning"

View patron's profile

patron

2244 posts in 219 days


posted 84 days ago

great work !

looking forward to the finish line .
thanks for the step by step ,
easy to follow ,
much food for thought !

-- david ,new mexico ,allheart

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