DIY Network

Making the Cork for the Ottoman Learn how to fill the ottoman mold with cork. From "Freeform Furniture" episode DFFF-206

Host Amy Devers applies a coat of wax to the inside of the mold for the ottoman. She mixes the cork with the epoxy and fills the mold. She puts the lid on, along with four sliding arm clamps and lets it dry.

After 24 hours, she removes the clamps. Lastly, she uses a power drill to disassemble the braces from the plywood mold.

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	Amy sands the cork for the ottoman.
	The room—Before
	The room—After

Materials:

pre-fabricated plywood cylinder
3/4" shop grade plywood
handle
screws
packing tape
scrap piece of wood
pen
wax
granulated cork
epoxy
plywood stirring stick
sand paper
sanding block
hollow stainless steel tube

Tools:

table saw
jig saw
combination square
straight edge ruler
hand clamp
router
circle jig
laminate trimmer
round-over bit
braces
mounting blocks
spring clamps
power drill
band clamp
sliding arm clamps
band saw
random orbital sander
150-grit sanding disc
hydraulic roll bender
computer numerical controlled (CNC) mandrel draw bender
TIG welder
awl
drill bit

	Figure A
	Figure B

Making the Cork for the Ottoman

1. Put a nice generous coat of wax all over the inside of the mold. That, in tandem with the tape is going to make a nice slippery surface.

2. Take 18 quarts of cork and mix it with the three cups of epoxy.

   Tip: Epoxy is a strong, two-part adhesive that consists of resin and hardener. It's highly toxic so make sure you wear a respirator and gloves when working with it.

3. The epoxy will start to harden up in ten minutes so you need to move fast. Pour a little bit of epoxy into the bucket with the cork grains, grab a plywood stick, and mix it together. Repeat this step each time to insure an even consistency.

4. Once you have the epoxy mixed evenly on the granules, you can start filling the mold. Push the mixture out with your hands, spreading the grains evenly as you go (figure A).

5. Once you get all the cork in the mold, put the lid on. Give it a couple of twists and then clamp it down with four clamps and let it dry for 24 hours.

6. Put four sliding arm clamps on either side of the mold (figure B). They exert just enough pressure for a tight, even bond.

7. Use a ruler to measure the exact distance between the lid and the top of the cylinder.

   Note: The measurements need to be consistent otherwise the shape of the cork won't cure evenly inside of the mold. If you are off even slightly, tighten or loosen the clamps to achieve an even surface.

8. After the epoxy has cured, remove the clamps.

9. Use the power drill to disassemble the braces from the plywood mold.

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

IMS Metal
Industrial Metal Supply Company
Website: www.imsmetals.com

Metal Powder Coating
Steve's Plating Corporation
Website: www.stevesplating.com

GUESTS :

Steve Knez
Steve's Plating Corporation
3111 N. San Fernando Rd.
Burbank, CA
Phone: 818-842-2184
Website: www.stevesplating.com