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Forum topic by docspencer posted 04-09-2014 03:57 PM 1063 views 0 times favorited 15 replies Add to Favorites Watch
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362 posts in 1973 days

04-09-2014 03:57 PM

I’m going to try and make a drink holder to use with a couch we have. It will have 3 sides and slide over the arms on the couch. I’ve attached a picture of one available from the company that made our couch. My question is this – I can round over the 2 outside edges where the sides meet the top. That’s easy. The problem is with the insides of this joint. Does anyone have any ideas? I’m stuck.

By the way – this looks like one piece of plywood that was bent. I plan to use 3 pieces.

15 replies so far

View mahdee's profile


3890 posts in 1795 days

#1 posted 04-09-2014 04:35 PM

A Band saw should do it. You will need to round the outer corner, measure the thickness of the wood and compensate the inside corners with a 45 degree cut triangle pieces. The pieces have to be thick enough to make the same thickness of the walls once you drum sand/band saw them to shape.


View Gary's profile


9333 posts in 3461 days

#2 posted 04-09-2014 04:39 PM

If by “round-over” you mean easing the edges, you can easily do that with the router. If that’s not what you mean, I don’t understand

-- Gary, DeKalb Texas only 4 miles from the mill

View CharlieM1958's profile


16275 posts in 4246 days

#3 posted 04-09-2014 05:08 PM

Other than using a band saw as mrjinx007 suggested, or making your own bent lamination, I can’t think of another way to duplicate that inside rounded corner. But is it really necessary for functionality?

-- Charlie M. "Woodworking - patience = firewood"

View MrFid's profile


876 posts in 1932 days

#4 posted 04-09-2014 05:26 PM

That looks like bent lamination to me. Like others have said, you can probably make a similar shape with a bandsaw.

-- Bailey F - Eastern Mass.

View Earlextech's profile


1162 posts in 2718 days

#5 posted 04-09-2014 05:40 PM

I would do a steam bent lamination.

-- Sam Hamory - The project is never finished until its "Finished"!

View docspencer's profile


362 posts in 1973 days

#6 posted 04-09-2014 06:54 PM

Thanks for all the quick replies and the ideas. To answer some of your questions -

1) Yes, I am talking about the inside or underneath corner – where the two side pieces meet the top.

2) The rounding the inside corner would be nice to have – I’m assuming since the store bought one has this it is good for where it contacts the couch arm.

3) I thought about the router, but I can’t figure out how that would work – wouldn’t the router base keep the bit from getting enough into the corner?

4) I don’t own a band saw…......

View RRBOU's profile


176 posts in 2320 days

#7 posted 04-09-2014 07:11 PM

With the router you could start with thick stock for the flat top. Use a core box bit of the same diameter as the radius you want on the outside to put a radius in the stock with the edge at the thickness of the sides. Then remove the waste between the radiuses. The top on the box in these plans is an example.
Then glue up the corners and radius the outsides.
I acutely use this design for a lot of tops and it works great. I do not use the dado blade to remove the waste though I use a 1-1/2” diameter flat bottom router bit and make shallow cuts to sneak up on the depth.

-- If guns cause crime all of mine are defective Randy

View ChefHDAN's profile


1067 posts in 2877 days

#8 posted 04-09-2014 07:14 PM

I’ll take the easy way out,,,
piece of cove molding applied to the inside joint, little glue few brads, you’ll get the look without the lamination hassle

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

View CharlieM1958's profile


16275 posts in 4246 days

#9 posted 04-09-2014 07:25 PM

ChefHDAN just beat to to that one!

-- Charlie M. "Woodworking - patience = firewood"

View docspencer's profile


362 posts in 1973 days

#10 posted 04-09-2014 08:57 PM

Great ideas RRBOU and ChefHDAN. I’ll play with each and see which one works out better!

View bondogaposis's profile


4769 posts in 2379 days

#11 posted 04-09-2014 10:04 PM

Buy a bandsaw, you’ll be glad you did.

-- Bondo Gaposis

View docspencer's profile


362 posts in 1973 days

#12 posted 04-09-2014 10:07 PM

If only bondo See if YOU can convince my wife.:)

View TheWoodenOyster's profile


1317 posts in 1963 days

#13 posted 04-09-2014 10:14 PM

I’m with chefdan. Steambending or bent lamination is overkill in my opinion for a project like this. That is unless you were looking for a small, inexpensive project try it on, then maybe go for it. Otherwise, cove molding sounds like the best idea to me.

-- The Wood Is Your Oyster

View NoThanks's profile


798 posts in 1557 days

#14 posted 04-09-2014 10:19 PM

Jig saw several pcs and stack them. Could be hardwood or plywood then veneer the outside.

-- Because I'm gone, that's why!

View docspencer's profile


362 posts in 1973 days

#15 posted 04-09-2014 10:22 PM

Another good idea. You guys rock.

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