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Jellyfish Table #4: Making The Oval

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Blog entry by Blake posted 07-03-2009 09:05 PM 3144 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

-- Happy woodworking! http://www.openarmsphotography.com



18 comments so far

View Karson's profile

Karson

34902 posts in 3124 days


#1 posted 07-03-2009 09:12 PM

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.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View majeagle1's profile

majeagle1

1418 posts in 2219 days


#2 posted 07-03-2009 09:19 PM

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

502 posts in 2530 days


#3 posted 07-03-2009 09:21 PM

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.

View lew's profile

lew

10129 posts in 2479 days


#4 posted 07-03-2009 09:50 PM

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!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Blake's profile

Blake

3437 posts in 2597 days


#5 posted 07-03-2009 09:52 PM

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

-- Happy woodworking! http://www.openarmsphotography.com

View dlcarver's profile

dlcarver

270 posts in 2453 days


#6 posted 07-03-2009 10:07 PM

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

4438 posts in 2686 days


#7 posted 07-03-2009 10:30 PM

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

-- Thos. Angle, Jordan Valley, Oregon

View pommy's profile

pommy

1697 posts in 2414 days


#8 posted 07-03-2009 10:32 PM

Blake the top is looking cool mate

Andy

-- cut it saw it scrap it SKPE: ANDREW.CARTER69

View Todd A. Clippinger's profile

Todd A. Clippinger

8791 posts in 2823 days


#9 posted 07-03-2009 10:59 PM

Awesome job!

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

View Beginningwoodworker's profile

Beginningwoodworker

13347 posts in 2396 days


#10 posted 07-03-2009 11:14 PM

The table looks great, Blake.

-- CJIII Future cabinetmaker

View patrick m's profile

patrick m

197 posts in 2536 days


#11 posted 07-03-2009 11:55 PM

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 (online now)

a1Jim

112537 posts in 2300 days


#12 posted 07-06-2009 02:52 AM

great job

-- http://artisticwoodstudio.com Custom furniture

View Karson's profile

Karson

34902 posts in 3124 days


#13 posted 07-08-2009 12:01 AM

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.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View blockhead's profile

blockhead

1452 posts in 2032 days


#14 posted 07-08-2009 11:54 AM

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

-- Brad, Oregon- The things that come to those who wait, may be the things left by those who got there first.

View Russel's profile

Russel

2199 posts in 2662 days


#15 posted 07-08-2009 02:18 PM

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.

-- Working at Woodworking http://www.VillageLaneFurniture.com

showing 1 through 15 of 18 comments

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