DIY Network

Finishing Touches to the Stackable Seats Host Amy Devers completes the stackable seats project by applying felt to top of the MDF. From "Freeform Furniture" episode DFFF-209

Freeform Furniture's stackable tray shaped chairs are completed by attaching felt fabric to the trays. Amy Devers starts by using a white wax pencil to trace the corners of the shape. She resets the felt on top of the MDF, uses a steam iron to create creases for the cushions and uses a heavy-duty fabric starch to help the felt keep its shape.

Finally, once the felt fits perfectly over the silicone, Amy attaches it using a spray adhesive.

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	Room: Before
	Room: After
	Freeform Furniture's Stacked Tray Seats
	The stackable chairs offer extra seating when company visits.
	Host Amy Devers finishes the stackable tray seats by ironing and applying the felt.

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

Finishing Touches to the Stackable Seats

1. First, center a piece of felt under the form and use a white wax pencil to trace the corners of the shape.

2. Rest the felt on the top of the MDF and firmly smooth it out over the edges.

3. With a steam iron, use firm even pressure, moving your way in and along the edges to create the creases you want for the cushion (see photo, above right).

4. Spray on heavy-duty fabric starch to help ensure the felt will keep its shape.

5. The felt now has the form it needs to fit perfectly over the silicone cushion. Next step is to adhere it to the seat with a high strength spray adhesive.

6. Put on a respirator because the spray adhesive contains harmful chemicals.

7. Apply the adhesive directly to the silicone and the tray. To help avoid overspray, place blue masking tape around the edges of the wood.

8. Spray an even coat on the back of the felt—as well for a more durable bond.

9. Use brown craft paper to keep the felt from sticking to the work piece as you line up the felt.

10. Pull the paper out, press the felt on and smooth out the edges with your fingers.

11. Peel off the blue tape you were using as a glue guard.

12. With a ruler, line up the feet. They will help protect the seats and the floors from any scuffs.

13. Use a scrap piece of wood to back the cut and trim off the excess felt with a utility knife (figure A).

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