Inventor Daryl Kiel has created a vacuum-molding machine that can make decorative curves on panel doors, drawer fronts and stair treads, giving any work piece a feeling of movement. The power of the VacuPress comes from its vacuum (figure A). The mold and surface to be veneered are placed inside a large plastic bag (figure B) that is sealed on three sides and attached to the vacuum hose on the open side. The vacuum sucks air from the bag, and eventually forces the work piece to conform to the shape of the mold underneath it.
The VacuPress system has two main functions: adding curves to wood and attaching veneer to wood. Here's how it's used to create a beautiful bent panel. Materials:
At least four pieces of hardwood for the mold (size and number of pieces depend on the work piece)
Router, jigsaw or band saw
Wood glue
Nail gun and nails
Bending plywood (same length and width of the base of the mold)
Veneer tape
Veneer
Foam roller
Carpenter's glue
Work piece to be curved and veneered
Masking tape
3/4"-thick piece of particleboard whose length and width is larger than the mold
VacuPress system
- To create the mold, start with one flat piece of hardwood the same size as your work piece to form the base. Use a router, jigsaw or band saw to cut the desired curve of the work piece into three or more pieces of hardwood, depending on the desired width of the mold. Attach the curved pieces perpendicular to the base, using glue and nails (figure C). Cut a piece of bending plywood (also called "wacky wood") to the same size as the base of the mold. Place the bending plywood over the top of the mold, and nail in place (figure D).
- Use veneer tape to cover the seams of the veneer (figure E).
- Use a foam roller to spread carpenter's glue over the surface to be veneered (figure F). Do not apply glue to the veneer.
- Place the veneer on top of the glue, and allow the glue to dry (figure G).
- Use masking tape to hold the work piece in place on top of the mold (figure H).
- Place the mold and work piece on top of a 3/4" scrap piece of particleboard. Place the particleboard, mold and work piece into the VacuPress plastic bag. Seal the bag.
- Turn on the vacuum. The vacuum will suck all of the air out of the bag, then begin curving the wood to the shape of the mold and securing the veneer tightly to the work piece.
RESOURCES :
Vacuum Pressing System
Website: www.vacupress.com
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