| Freestanding Mirror -- Bent-Lamination Legs |
From "Wood Works"
episode WWK-109 |
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Master woodworker David Marks demonstrates the steps in the construction of the frame and legs for a freestanding mirror. With its strong frame of cherry and bent legs, this piece is representative of the spirit of contemporary woodworking. Branchlike curved legs sweep gracefully upward, and the center post is adorned with dovetail-shaped ebony handles for the locking pins. The oxidized cherry wood creates a rich border for the mirror's reflective glass. Made from solid cherry wood, the freestanding mirror is made using a bent lamination technique. The legs are joined with a third member to create a stand that allows the mirror to swivel and lock in various positions. The frame for the mirror is constructed using loose tenon joinery, and the entire piece is sun-oxidized for a darkened-cherry finish.
Materials: Cherry stock
MDF (for building shaping-form)
Band saw; six-tooth hook blade
Clamps
Plastic resin glue
Chalk or carpenter's pencil
Saftety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his website -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc. Creating the Curved Laminate Legs One of the most striking features of the freestanding mirror is the set of curved legs. Their look is elegant, but they are a challenge to build. For this project, drawings were made first, and a full-scale prototype was made for the legs. The prototype was then used to generate the shaping form (figure A) that would be used to create the curves on the final version of the leg pieces. The strips of cherry are set in place on the form, and pressure is then applied to bend the wood with clamps. The form, made from three 1/2" sheets of MDF, is strong enough to bear the pressure needed to bend the strips. This is a technique known as bentwood lamination. Thick strips of cherry stick were sawn into 1/16" strips, making them easier to bend (figure B). The thin strips are pliable enough so that they can take the shape of the form.
Steps:
- To cut the 1/16" thin strips of cherry, a six-tooth hook blade is used on the band saw (figure C). Using a new blade is recommended, because sharper blades will yield a cleaner cut.
- Once the individual strips have been cut, they are held together in a bundle -- in the order in which they were cut -- and a triangular mark is made across the edge formed by the individual pieces. The triangular mark is helpful in lining up the individual properly during the glue-up process. In that way, the grain will match, and the bundled strips will look like one solid piece once they are glued up.
- Use a slow-setting plastic resin glue to glue the strips into the bundle (figure D). The development of modern adhesives like resin glue are what make the bentwood lamination technique possible.
- Once the laminates have been glued together, the bundle is ready to be placed into the form. Use packing tape to line the curved, contacting surfaces of the form in order to prevent the glue and laminates from sticking to the form. A layer of cork may also be used on the concave face of the form to serve as a cushion to alleviate any imperfections in the form or laminate. The cushion of the cork helps to ensure a tight glueline.
- With the form prepared, the stack of glued laminates is lined up on its edge, bent and placed into the form (figure E).
- Use clamps to apply pressure to the form and hold the laminate in its bent shape as the glue hardens (figure F).
- Even clamping pressure is key in ensuring that the cherry strips take on the shape of the form (figure G).
- Leave the piece clamped overnight as the glue dries to ensure that the laminate holds a tight curve.
With the laminate legs glued into shape, the next phase of the project highlights completion of the legs and assembly of the mirror's base. Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
Beds and Bedroom Furniture: The Best of Fine Woodworking
Model: 1561581917
Author: Editors of Fine Woodworking
(1997)
The Taunton Press Inc.
Website: www.taunton.com
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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