DIY Network

	WOODWORKING Index
	Antiques Bedroom Seating Chests Decorative-Accent Furnishings Shelves & Cabinets Tables Products Woodworking Shop Other

BEST OF WOODWORKING

Mold Quiz
Home Safety
Room Planner
Pet Care Guide
Weekend Projects
DIY to the Rescue
Sparkling Solutions
Organize Your Home
Ultimate Media Room
Picture Perfect Parties
Queen of Clean

SPONSOR LINKS

Making the Curves

Learn how to create the curves for the MDF fire screen.

From "Freeform Furniture"
episode DFFF-204

Host Amy Devers makes a template for the MDF ribs. She draws the shapes on craft paper, cuts the shapes out and uses spray adhesive to attach the shape to the tempered hardboard. She uses a band saw to make the curves and an oscillating spindle sander and a disc sander to clean them up.

Amy creates curved medium density board for the decorative fire screen.

The fireplace is white on white "before"...

Amy works her magic with this unique bright red fire screen.

The intricate curved pieces set this piece off from other decorative fireplace screens.

Materials:

craft paper
straightedge metal ruler
tape measure
triangular ruler
flexible curve
scissors
spray adhesive
tempered hardboard
respirator
3/4" sheets medium density fiberboard (MDF)
1/2" sheets medium density fiberboard
white glue
double-stick tape
threaded inserts
nut
washer
two-part epoxy
sandpaper
primer
water-based semi-gloss paint
aluminum spacers

Tools:

band saw
oscillating spindle sander
disc sander
vacuum press
router
flush trim bit
round over it
cordless drill
awl
mallet
drill press
forstner bit
hex key (Allen wrench)
socket wrench

Figure A

Figure B

Figure C

Figure D

Making the Curves

Safety Alert: This is a decorative fire screen. This is NOT to be used or placed in front of a real wood burning fire place under any circumstance!

You need to make a template out of the MDF ribs. Draw the shape first on craft paper.
Using a straightedge ruler, draw out a long, thin line to start off a rectangle. Each of the 14 pieces should fall within a 42" length, so mark that dimension out with a tape measure.
Use a triangle ruler to draw the ends of the rectangle (each of which is 5").
Once you have the rectangular perimeter down, use a flexible curve (figure A) to trace the free-flowing lines for the fire screen.
Cut the shape out of the paper.
Use spray adhesive to attach the shape to tempered hardboard.
FYI: Tempered hardwood is another wood product that is made from thin sheets of compressed sawdust and wood chips, and it is perfect to use for templates because it is inexpensive.
Safety tip: because the spray adhesive is toxic, you need to wear a respirator. Whenever you work with chemical sprays, make sure to work in a well-ventilated area.
Spray an even coat on the pre-cut tempered hardboard and then on the craft paper.
Place the paper directly on the hardboard and press it into place.
Lower the blade guard of the band saw about an inch above the work piece.
As you feed the hardboard in and around the band saw to make the curves, take it just to the outside of the line.
Note: There are two different types of curves used (figure B)—concave curves, which are curves that slope inward, and convex curves, which are curves that protrude.
Turn on the oscillating spindle sander making sure the template is not touching it. Slide the inner curves in and around the curve of the spindle.
Slowly move the curve around the spindle pushing it gently against the abrasive to shape the curve (figure C).
Clean up the convex curves on the disc sander (figure D).