Aalto Inspired Tea Cart #3: Refining the laminations and underwater basket weaving

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Blog entry by bfd posted 07-13-2008 07:32 PM 1953 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 2: The Wheels are in motion! Part 3 of Aalto Inspired Tea Cart series Part 4: Fixing a routing mess up. »

Did I mention how over my head I am with this project? Well after taking a week off from woodworking between a trip to Vegas and not being able to work in the shop due to the smokey air in the Sacramento area I am back to work. Now that I have the laminations glued up I needed to figure out a way to trim them down to finished width. I intentionally glued the laminations up at 3 1/2” knowing that I needed to yield a 2 1/2” wide leg. This was a challenge since I couldn’t use my 6” jointer to clean up the edge nor could I use my Bandsaw or Table saw due to the shape. To be honest I didn’t think this through and didn’t discover this until I was working on my test piece. How do I clean up these edges? I decided to use my bending forms as a reference point to clean up the edges. putting the laminations back in the form I let one edge pertrude from the form and set the form on its side. I made a simple sled for my router and began the task of routing the edge down until it sat flush with the form.

I followed this up with a belt sander. This established one flat side which I was then able to reference for the second side. I flipped the form over and followed the same procedure to bring the second side down to just shy of final thickness.


I needed to do a little filling on the edges so I made a mixture of some titebond II, a little water, and some sawdust that I collected from sanding.


Now time to break out the card scraper and do some hand sanding and cut to final length.



Finally I again used my router this time with 1/8”round over bit to ease the edge. Here they are all cleaned up.



Now to do some veneering. The lower tray of the tea cart calls for a veneered surface so I layout the veneer and decide to lay it up with a slip match. (I like the way quarter sawn grain looks slip matched).

I trim up the veneer using a flush trim bit and router placing the veneer between two jointed pieces of plywood. This made it easier to joint the edge at the jointer.


I edged glued the veneer together both front and back and glue to some 1/2 birch ply. since I don’t yet have a vacuum press I pressed it between some melamine and particle board and clamps.


The other thing I needed to figure out was how I was going to build a woven wood basket that the client wanted. So after thinking about it I come up with a way to build a basket and I do a partial mock up. It envolves soaking the wood in water to loosen the fibers. When I go to do the real basket I will use only the tight parallel grain. Well off to work thanks for checking this out.





5 comments so far

View gizmodyne's profile


1780 posts in 4265 days

#1 posted 07-13-2008 10:48 PM


Great solution with the router and the forms.

Can’t help you out on the seat.

Keep up the good work.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke."

View Betsy's profile


3391 posts in 4071 days

#2 posted 07-14-2008 01:26 AM

Pretty interesting. Looking forward to more progress. Looks like it’s coming along nicely.

-- "Our past judges our present." JFK - 1962; American Heritage Magazine

View ChicoWoodnut's profile


904 posts in 3991 days

#3 posted 07-14-2008 03:31 AM

Looks great! Keep at it. I really like the posts too. Some bent laminations might be in my future.

-- Scott - Chico California

View bfd's profile


502 posts in 3982 days

#4 posted 07-15-2008 02:04 AM

Thanks Guys & Betsy.

View MsDebbieP's profile


18616 posts in 4336 days

#5 posted 07-30-2008 12:56 PM

that’s amazing!!
great process blog as well

-- ~ Debbie, Canada (, Young Living Wellness )

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