| Project by Lee A. Jesberger | posted 867 days ago | 1295 views | 2 times favorited | 24 comments | ![]() |
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In the home office project, there are large curved door. At the time of writing about the project, the pictures showing the form work were mixed in with over a thousand other pictures.
Well, we found them, and I thought some people would like to see how it was done. To be honest I forgot how it was done, and had to ask my employee / partner. I guess old age is setting in early.
He is the same guy that introduced me to vacuum systems originally.
See: http://www.prowoodworkingtips.com/Vacuum_Systems_pg_1.html
The two layers of 3/8” bendy ply is inside the bag, already glued. The plywood is clamped at the bottom of the form, bent over the form, and then clamped at the top. The the bag is turned on and the vacuum is pulled. The green felt is inside the bag to permit the air to be pulled out of the entire length of the glued up parts. Without the felt, the bag would suck tight to the plywood, and leave air in the far end of the bag.
If this form were to be placed in the bag, it would be crushed in short order.
Add this technique to your repertoire and your woodworking can move up to another level with possibilities.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com































24 comments so far
Roger Strautman
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534 posts in 1028 days
posted 867 days ago
Lee, it looks like the door was made wider than needed because of the screwed board along the front bottom. I assume this was done cut it a to perfect width and fit? Thanks again Lee!
-- " All Things At First Appear Difficult"
Karson
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25800 posts in 1295 days
posted 867 days ago
What did you have as the caul on top of the veneer?
great perspective.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
DAN
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6439 posts in 877 days
posted 867 days ago
thanks for the posting. I’m following your project contributions and getting many ideas. Keep them coming. Show and tell is a great way to learn.
-- work from your heart and your spirit will live forever
Damian Penney
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1030 posts in 886 days
posted 867 days ago
Karson, no caul needed as that’s what the vacuum bag is used for (applying lots and lots of pressure evenly across a surface) – if that’s what you meant.
To form the bendy ply had you just clamped it to that form previously?
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Hi Roger,
We make them oversized to permit us to square it up later. Pieces have a tendency to slide in the glue up process. The extreme pressure and the glue cause it to move rather easily.
When made oversized, we don’t have to be overly concerned about it.
Although, even if they were made to exact size, filling the holes with bondo wouldn’t be a problem.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Hi Karson,
No cauls were needed with this process. One of the fine points of vacuum bags is there is no need for cauls.
The pressure is evenly applied.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Thank you Dan.
I’ll try!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Hi Damian,
Correct, clamp the bottom , making sure both sheets are tight to the table, bend the bendy board, clamp it at the top and turn on the vacuum.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Damian Penney
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1030 posts in 886 days
posted 867 days ago
Oh cool, I didn’t know that would work. When I said just clamp and glue I didn’t think the press was involved. I’d assumed the bag would have tried to flatten itself pulling the sheets towards a horizontal plane. Do you use felt in the bottom of the bag too then so all the air can escape or is having it just on top good enough? I’d also just like to say thanks again for all the hints, tips and how-to’s you’ve posted, I’ve already learnt a huge amount from your posts so much appreciated.
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
Bob Babcock
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1808 posts in 980 days
posted 867 days ago
Your methods astound me Lee. Great stuff.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Hey Damian;
No, no need for the field on the bottom of the bendy ply. The vacuum is strong enough to pull air thru the plywood!
Thank you for the kind words. Sharing what I’ve learned is becoming one of my biggest pleasures!
A good friend friend of mine in his early seventies, was a master plasterer with skills that took a lifetime to learn.
His worst fear, which did happen, was dying before being able to share his knowledge. He was a third or fourth generation plasterer, who was absolutely incredible. I hope one day to be as good at what I do, as he was at what he did. A terrible waste!
That may have something to do with my desire to pass along what I’ve learned. And the fact that someone taught me, whether it be a book, employee,(as is often the case), or the school of hard knocks. I do have a P.H.D. from that fine institution!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Hi bob;
Not really my methods Bob, just things shared with me, added to, and passed along!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Don
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2590 posts in 1071 days
posted 867 days ago
When I see beautiful work processes like this, it make me feel a little foolish showing the small items that I make.
Thanks, Lee.
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
Lee A. Jesberger
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3710 posts in 874 days
posted 867 days ago
Don,
Some of my most favorite projects have been small items like dead blow hammers, or the cook book stands, and the like. If I can find the pictures of the dead blow hammers, I’ll post some of them. The are beautiful, and we get to use them while making other things.
They are not overwhelming like larger projects can be, take only a small amount of space, and the pride in what you made part comes along much quicker.
A work of art, is a work of art, regardless of size. (at least that’s what I tell my wife anyway) LOL
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
mot
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4902 posts in 931 days
posted 867 days ago
I don’t even know what to say to this, Lee. I’m looking at those pictures like a Labrador dog that you are speakin Chinese to. A head tilt and confused look. I truly look at your work with awe and wonder. As you can see, I haven’t had a chance to get on the site in a few days, so I’m just engorging myself with the amazing content that such skilled and knowledgeable people are providing here. Lee, you are upper echelon!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
TomFran
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2513 posts in 888 days
posted 866 days ago
Lee,
You do awesome work, but aren’t you worried that some of us L J’s will steal your techniques and designs and siphon off some of your buisness ;^D
-- Tom, Surfside Beach, SC - Romans 8:28
MsDebbieP
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14158 posts in 1055 days
posted 866 days ago
but then… he’s just making this up… so what’s to steal?? :)
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Lee A. Jesberger
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3710 posts in 874 days
posted 866 days ago
Hi Tom;
I suppose if they were my ideas, nah, I would still spill the beans.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 866 days ago
Exactly Debbie,
I would just make up something else. Hah!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 874 days
posted 866 days ago
Hi Tom.
You just described how I look when I’m trying to figure out how to build something. But since I have boxers,
I probably look like them!
I look at the drawings and wonder, aw what did I get into this time?
Your words are too kind.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Bill
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2561 posts in 1056 days
posted 864 days ago
This is a great learning experience for me, as I would not known how this would be done. You are able to turn out some incredible work Lee. If you were not so far away, I might be camped out at your shop just to work there and learn.
-- Bill, Turlock California, http://www.brookswoodworks.com
Lee A. Jesberger
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3710 posts in 874 days
posted 862 days ago
Thanks Bill, for the kind words.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
mmh
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1385 posts in 617 days
posted 401 days ago
Can we see the finished product? Looks impressive.
-- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe
Lee A. Jesberger
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3710 posts in 874 days
posted 399 days ago
Hi mmh;
Here’s the link to the finished project:
http://lumberjocks.com/projects/1846
And a link to a custom desk for the same room:
http://lumberjocks.com/projects/1844
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com