DIY Network

Water-Jet Cutting and Applying Industrial-Grade Felt Chair seats are cut and felt attached From "Freeform Furniture" episode DFFF-107

Host Amy Devers visits an expert who cuts the seats using high-pressure jets of water, and then an industrial-grade felt is applied to the dining room chairs.

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Amy has the chair seats cut by water-jet technology and then applies the industrial grade felt.

Materials:

Industrial felt
Low density polyethylene
1/2" diameter stainless steel rod
Face shield
Work gloves
Tank of argon gas
Welders mask
Welding gloves
Leather welding gloves
Weather welding jacket
Filler rod
Industrial spray adhesive
Blue tape
Utility knife
Large piece of cardboard
Industrial construction glue
Tape measure

Tools:

Metal-cutting chop saw
TIG welder
Welding jig
Water-jet cutter
Clamps
Drill press
Mallet
Cauls

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H
	Figure I
	Figure J
	Figure K

Water-Jet Cutting and Applying Industrial Grade Felt

FYI: Water-jet technology can be used to cut a variety of things including metal and plastic. Basically water is fed through a cutting head (figure A) at 55,000 pounds per square inch (psi) and then mixed with an abrasive. Water alone fed at 55,000 psi's can cut a variety of things, but adding an abrasive increases the strength nearly 10,000 times.

In order to get the water pressure up to 55,000 psi, water is brought in through a series of filters and then pressurized by a pump (figure B).

The design for the seat bucket is programmed into a computer and the computer actually controls the cutting head by telling it where to cut and how fast to make the cut. The slower it moves, the better the cut it makes (figure C).

1. Once the seat buckets are cut, the process is repeated for the chair brackets. The plastic for the brackets is a little thicker than the seat buckets so the cutting head moves a little slower to insure a smooth cut.

2. Once all the pieces for the chairs are cut, you need to apply the industrial felt to the poly flat.

   Note: Industrial grade felt has a lot of durability. It can really withstand wear and tear. They use it to cushion the vibration from industrial machines--so you know it has to be tough.

3. To apply the felt, use an industrial spray adhesive (available at hardware stores). When you use the spray, be sure to work in a well-ventilated area and wear a respirator.

   Note: The corners will be used to bend the seats into shape, so they won't be getting covered with felt.

4. Mask off the corners with blue tape to avoid spraying adhesive in the corners. After the tape is on, cut a piece of felt a little bigger than the poly flat (figure D).

5. Lay the felt out on a large piece of cardboard.

6. Apply an even coat of the spray adhesive over the entire surface of the felt.

7. Spray an even coat of the spray adhesive over the entire surface of the felt (figure E).

8. Spray an even coat of glue on the top of the poly flat. Then let the glue dry for approximately a minute.

9. The next step is to apply the felt to the seat. To do this, simply lay the seat flat onto the felt. Press the poly flat onto the felt.

10. With a razor knife trim off the excess felt, being careful to keep the blade perpendicular to the poly flat (figure F).

11. Cut the excess felt off the masked tabs, and remove the tape.

12. Fold it up to become the seat bucket. The plastic is going to come together to form the glue joint.

    Note: Use an industrial, structural glue. You need one that is formulated specifically for this kind of plastic which is called a polyolefin and is so strong that the plastic will break down before the glue does!

13. Apply the glue to one tab using the special applicator that comes with the glue (figure G).

14. Simply lift the back of the poly seat up, folding the tabs in, and overlap the front tab over the back tab (figure H).

15. When the front tab reaches the felt, put a clamp on the overlap.

16. Repeat the process on the other tab making sure that the folds match and the seat bucket is even on both sides.

17. The seat bucket is folded and drying.

18. The brackets that were water-jet cut (figure I) are going to hold the seat bucket to the chair frame. Mill the holes that allow it to slot down onto these spots. First, measure the distance from the center of each rod.

19. Then, mark out that dimension onto the brackets making sure that the holes are spaced evenly from side to side.

20. Drill the holes in the brackets using a drill press (figure J).

21. Glue the brackets on the seat posts. Use the same glue used on the seat bucket. This will give a rock-solid bond with the stainless steel.

22. Apply a little bit of glue to the holes in the brackets, and slide it onto the posts of the chair frame (figure K). Repeat the process for the back bracket.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Plastics
Poly Hi Solidur
Website: www.polyhisolidur.com

Welding Tools and Accessories
Steiner Industries
Website: www.steinerindustries.com

Miller Electric Manufacturing Co.
Website: www.millerwelds.com

Smith Equipment
Website: www.smithequipment.com

Waterjet Services
Flow International Corp.
Website: www.flowcorp.com

Greek Marble, Inc.
Phone: 323-221-6624

GUESTS :

Elliot Monson
Senior Applications Technician
Flow International Corporation
23500 64th Ave. S.
Kent, WA 98032
Phone: 253-850-3500, ext. 593
E-mail: jbailey@flowcorp.com
Website: www.flowcorp.com