This weekend I was able to resaw all the veneers for the top from the figured sapele. These three boards started out as a single 9/4 board 16’ long. There was quite a bit of bow and twist to take out, but light passes with the jointer flattened one face with minimal chip out.
Once I had a flat face I was able to resaw into veneer. The figured sapele proved to be far more difficult to resaw than the quarter sawn I used for the bottom veneers. The blade had more of a tendency to wander and the boards moved a bit after each cut and required a few light passes on the jointer to obtain a flat face for the next resaw.
To be sure I kept the individual pieces of veneer in order, the ends were marked to show which board they came from (using lines on the left- this is board 4) and orientation (using the “V”).
I then switched to a 60 grit belt on the drum sander and cleaned up the sawn face.
I had to remove more material than I had hoped to clean up a few errant saw marks, but I ended up with veneers about 3/32” thick. I was amazed by the amount of sawdust produced by resawing and sanding these veneers, I filled up an entire dust collector bag!
By the end of the weekend I had 60 pieces of veneer sliced, sanded and ready to laminate.
Next step is to laminate the veneers into “boards” to be used for the top. My cores will consist of two layers of 3/4” Baltic birch plywood with a quarter sawn veneer on the bottom and a figured veneer on the top. This will require 5 sheets of Baltic birch, so I headed off to the plywood distributor for material. After I saw up the plywood core strips, I can start vacuum bagging the boards.
My CNC routing templates were ready, so I picked them up. There are two templates for the top. The faceted template will be used to route the laminated cores. Each facet will get a border of quarter sawn sapele. The larger elliptical template will be used to route the final table profile after the border segments are all attached.
Since this table is elliptical, each of the segments is slightly different. The templates marked E1 – E4 in the photo below will be used to pattern route the segmented border pieces. B1 and B2 are the templates for routing the base components and have the usual cloud lift along the top. The small bundle of templates in the lower left are for the ebony splines. Like the segmented border, each spline is slightly different to match the ellipse profile correctly.
Things are starting to take shape!
-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"