DIY Network

Fire Screen MDF Ribs Amy prepares the MDF ribs for the fire screen. From "Freeform Furniture" episode DFFF-204

Host Amy Devers prepares the MDF ribs. She spreads white glue on both sheets of MDF and sandwiches them together. She uses the pressure of the vacuum press to clamp the sheets together and then uses the template to trace the shape onto the MDF.

Next, she rough cuts them out. Double-stick tape attaches the template to each piece of MDF, and Amy then guides the rib around the router bit to shave off the excess material, and drills holes through the ribs for the threaded rods. She countersinks the nut and washer and drills two flat-bottomed holes. She then uses a regular drill bit to create the through hole to insert the threaded rod and drops a little bit of two-part epoxy into the hole and then screws in the threaded insert with a hex key.

Lastly, she sands off any blemishes and fares out any inconsistencies.

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	Amy works on the MDF ribs 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

MDF Ribs

Safety Note: 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!

1. Spread an even layer of regular white glue on both sheets of MDF and then sandwich them together.

2. When there is an even coat on both pieces, flip the MDF over and stack them up.

3. After you slide the MDF into the vinyl bag, seal the end using a plastic tube (figure A) and the C-channel that comes with the vacuum press.

4. Roll the bag over the tube and then snap the C-channel into place to give the bag an airtight seal. Flip the switch and let the vacuum pressure do all the work (figure B).

Note: A vacuum press is basically a vinyl bag that is hooked up to a vacuum pump. The bags come in various sizes. The machine exerts a tremendous amount of pressure—about 1,200 pounds for every cubic inch. This type of system is perfect for projects like this when pressure clamping is needed over a large surface area.

5. After about four hours of dry time, take the MDF out of the bag.

6. Take the tempered hardboard template, put it on top of the MDF and trace out the shape.

7. When the shapes are all traced, take them over to the band saw and rough cut them out

8. At the router table, use strips of double stick tape to attach the template to each piece of MDF.

9. Carefully guide the rib around the router bit (figure C) to shave off the excess material, get it to the size you want, and then create a smooth, soft edge.

10. Route a little round-over profile on the MDF ribs using a 1/8" round-over bit.

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