LumberJocks

THE MAKING OF A COFFE TABLE (PART ONE )

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Blog entry by kiefer posted 542 days ago 1642 reads 3 times favorited 10 comments Add to Favorites Watch

This is a blog of a build of a coffee table that I have been mulling over for about a year and finally started building it as my wife likes the idea so far, I build a some what crude model to give her a better picture then I could draw.!

OK this is the basic concept but the final design will be done in the shop and be different then what you see .
To start I build a form for the two base arches and I did not take pics of the build but it is simply five identical curved 1/2” plywood ribs on a sheet of 3/8” MDF and a top sheet of 5mm plywood reinforced with 2×4 along the top and bottom ends .
All is glued with yellow glue and stapled .
The form has to be very precise in shape ,to accomplish this I made a pattern rib and copied four more from it with the band saw and final cut the curve on the table saw . The clamp holes (1 1/2” ) I forgot to drill before assembly and drilled them after with a cordless drill ,oh well it works .

I also made a simple set of cowls from 2×4 which I simply jointed to a slight taper from both ends ,this is to apply pressure at the center of the lamination as I can only clamp at the outside edge of the form.

Now to the laminating process .
Four layers of spruce 3/8” construction plywood cut cross grain with yellow carpenters glue ,two sheets at first .
Everything marked for centre before placing on the form and aligned with the centre marks of the form .
I clamped the top centre cowl first and then pulled down both ends and screwed the end cowls on to the top player and clamped in place .The end cowl has shallow drilled pockets for the clamp pads to keep them from slipping .
Now the I put on the remaining cowls and let it set for two hours .
Then I glued up the second set of two sheets again using a paint roller and tray ,this works fast and gives a nice even coat of glue .
After letting everything set up for 24 hours I removed the clamps and repeated the process for the second arch .


Here are the two arches and the curves turned out well ,nice and even and good in thickness all over .

This is it for this installment .
The next part will be the layout of the cut lines .
Any comments and questions welcome .

-- Kiefer 松



10 comments so far

View lanwater's profile

lanwater

3070 posts in 1518 days


#1 posted 542 days ago

Great work Kifer.

What is the radius of the arch?
Is the plywood bendable ply?
How difficult was it bend?
Any breakage during the bending?
Did you get lot of spring back from using yellow glue?

I wanted to build a similar coffee table but gave up because I could not find bendy ply at a reasonable cost.
It looks like I could do the same thing you are doing.

-- Abbas, Castro Valley, CA

View eddie's profile

eddie

6852 posts in 1198 days


#2 posted 542 days ago

Kifer looking good ,looking forward to this my friend, looks like a little work out with those clamps once you get going

-- Jesus Is Alright with me

View stefang's profile

stefang

12402 posts in 1918 days


#3 posted 542 days ago

I like your wife’s basic design Kiefer and the thoughtful and methodical way you are tackling the laminating bending process. Looking forward to the next installment!

-- Mike, an American living in Norway.

View jaykaypur's profile

jaykaypur

3224 posts in 992 days


#4 posted 542 days ago

Looks good so far and can hardly wait to see the finished piece.

-- Use it up, Wear it out --------------- Make it do, Or do without!

View woodshaver's profile

woodshaver

2717 posts in 1937 days


#5 posted 542 days ago

This is very interesting Kiefer. Looks like most of the questions were ask before I got here so I’ll just sit back and enjoy this post. I’ll be looking forward to the next installment aslo.

-- Tony C , My high school shop teacher said "You can do it"... Now I can't stop!

View shipwright's profile

shipwright

4807 posts in 1382 days


#6 posted 542 days ago

Very good lamination and the design is excellent.
This will be a fun blog to follow.
Thanks for posting.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/

View ruddy's profile

ruddy

390 posts in 1523 days


#7 posted 541 days ago

Keifer…a great blog.
I do like the design and look forward to the next instalment.

-- And my head I'd be a scratchin'

View kiefer's profile

kiefer

2937 posts in 1251 days


#8 posted 541 days ago

Thanks to all of you for the comments ,much appreciated and gives me encouragement .
The design will evolve as I build this table with input from my wife and should be fun to build as it is for ourselves ,be patient with me it’s going to take a while but will keep you posted and bored with the details .
IANWATER
Take a look at this simple jig I posted some time ago. http://lumberjocks.com/projects/49135
I drew the arch by simply using the length of the base and high taking into consideration the thickness of the lamination .
A calculation could probably determine the radius .
The cross cut spruce ply bends quite well and I have used this process for some time with success .
There is some crackling going on during the bending process but no breaking . As to the use of yellow glue there seems to be no issue with creeping and very little spring back and some of that can be eliminated by sightly over bending ( using a slightly smaller radius for the form ) and placing dowels through the thickness of the lamination ,I have used this method in curved handrails and other applications .
The cost of this table will be minimal as all materials are inexpensive and also some recycled .

-- Kiefer 松

View lanwater's profile

lanwater

3070 posts in 1518 days


#9 posted 541 days ago

Thanks Kiefer, much appreciated!

I will be following with great interest.

-- Abbas, Castro Valley, CA

View Roger's profile

Roger

13953 posts in 1388 days


#10 posted 541 days ago

One heck-of-a build. Nice process, and how-to

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

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