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Fire Screen MDF Ribs

Amy prepares the MDF ribs for the fire screen.

From "Freeform Furniture"
episode DFFF-204

(Continued from page 1)

Figure D

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!

11. Every single one of the ribs need holes drilled through them for the threaded rods that are going to hold everything together. Slightly offset the ribs to give the piece a more visual interest. That means the holes will have to be offset also.

12. The holes for the template have already been drilled and will be used as a drill guide. You should have two sets—the A set and the B set (figure D). That will help you keep track of the offset holes.

13. Put an awl in the hole and tap it to mark where you want to drill.

Figure E

Figure F

Figure G

14. Mark the A and B sets on the template by choosing the most aesthetically pleasing position. The distance between the A and B holes must be exactly the same on both sides in order to achieve the effect you want with the ribs.

15. Drill the holes on the drill press. Use a bit that is slightly larger than the 1/4 threaded rod that will go into the hole.

Note: The drill press is a vertical drilling machine designed to drill holes at precise angles (figure E). If you don't have a drill press, you can also use a hand-held power drill.

16. Mark the holes in the B position for the top piece.

17. Set the depth on the drill press to bury the threaded insert (figure F) into the rib but not go all the way through. Drill the hole for the threaded insert.

18. For the bottom, the threaded rod gets capped off with a nut and washer, so you need to countersink the nut and washer.

19. Mark the holes in the A position. First, using a 3/4" bit, drill two flat bottomed holes. The forstner bit is guided by the outside rim of the bit itself. That means it can be used to drill a flat bottomed hole to counter sink the nut.

20. Change to a regular drill bit to create the through hole where you will insert the threaded rod. Line it up directly in the center of the hole and drill all the way through.

21. Install the threaded inserts into the holes.

22. Mix up a little two-part epoxy to give a little extra holding power. Drop a little bit into the hole and then screw in the threaded insert.

23. Take a hex key and drive it in (figure G). A hex key is also called an Allen wrench or hex head wrench and it drives in screws with a hexagonal socket in the head.

24. Use sandpaper adhered to a piece of laminate with double stick tape to sand off any blemishes and fare out any inconsistencies.

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