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 .