DIY Network

Seat Base Amy Devers begins the project by making the tray, which is also the base of the seat. From "Freeform Furniture" episode DFFF-209

Host Amy Devers begins the stackable tray shaped chairs project by creating the tray—or the base of the seat. She starts by laminating together three layers of 1/8" bending ply with urea formaldehyde glue, and the lays them together with cauls. She slides the whole package into a vinyl vacuum bag and spreads epoxy glue on each piece of plywood with a brayer, lines up the pieces and seals the bag.

Finally, once the wood is dry Amy trims down the laminate with a laminate trimmer with a flush trimming bit.

advertisement

	Room: Before
	Room: After
	Freeform Furniture's Stacked Tray Seats
	The stackable chairs offer extra seating when company visits.
	The first step is to create the base for the seats.

Materials:

laminate
1/8" bending ply
urea formaldehyde glue
bending form
vacuum bag
adhesive
vinyl gloves
strapping tape
plastic tube
C-channel
respirator
2 part epoxy glue
flush trimming bit
veneers
foam roller
contact adhesive
plywood
wipe-on polyurethane
MDF
mold release
wax mold release
cotton rag
melamine laminate
closed cell foam
silicone mixture
felt upholstery
foam
white wax pencil
heavy-duty fabric starch
spray adhesive.
blue masking tape
brown craft paper
ruler

Tools:

brayer
laminate trimmer
J-roller
utility knife
sanding block
power drill
steam iron

	Figure A
	Figure B
	Figure C

Seat Base

1. To begin constructing the seats, you need to laminate three layers of 1/8" bending ply with urea formaldehyde glue. The plywood needs to be cut down to size and a little bit oversized for the finished dimensions. Mix some glue and start spreading it on. The adhesive is toxic so put on a respirator and vinyl gloves before you get started. Use the two-part epoxy glue—one part is a resin and the other is the hardener, or catalyst. So mix the resin and catalyst and stir for a minute.

   Note: Resin kits start at $25.00 and can be found on specialty online suppliers.

2. Spread a thin coat on each piece of plywood with a brayer. A brayer is a small, solid plastic roller (figure A). The brayer doesn't absorb any glue, so it is a good way to make the glue go further — more than a foam or sponge roller would.

3. Once you have lots of glue on, line it up on the form on the center marks on the form. Use an extra layer of bending ply with taped edges as a caul.

4. Use some strapping tape to adhere it to the form. That will keep it registered while you slip it in the bag.

5. Seal the end of the bag using a plastic tube and the C-channel that comes with the vacuum press.

6. Flip it on and let the vacuum press do the work (figure B). A vacuum bag is basically a plastic bag that is hooked up to a vacuum pump. The machine puts approximately 1,200 pounds of pressure on every cubic inch of the piece as it sucks out the air. That is how it bends the wood.

7. Once the bends are fully pressurized, let the tray dry overnight so the tends can fully set.

8. Now it needs to be trimmed down and that is done in two stages.

9. Trim the long sides using a laminate trimmer with a flush trimming bit (figure C).

10. Try and keep your hand steady and work your way around the form until the sides of the tray are nice and smooth.

11. Trim it down to the right height.

Note: A template was made out of tempered hardboard for the shape you want.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.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

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

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

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

MacBeath Hardwood
Website: www.macbeath.com

Vacuum Pressing Systems, Inc.
Website: www.vacupress.com