DIY Network

Finishing the Cork Ottoman Learn how to finish the ottoman by trimming the cork and attaching the steel tube base. From "Freeform Furniture" episode DFFF-206

Host Amy Devers trims the edge of the cork and sands the surface. She goes on a field trip to bend the metal tube for the base, and lastly, she drills pilot holes and attaches the steel tube base to the cork ottoman to complete this unique project.

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	One of the finishing touches is to attach the legs to the cork 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

Finishing the Cork Ottoman

1. Trimming the edge down is an easy cut on the band saw (figure A). Draw a straight line as a guide.

2. After a single, quick cut on the band saw, use the random orbital sander (with 150-grit sand paper) to smooth out the cork.

3. Use a scrap piece of sandpaper, a sanding block, and a little elbow grease to soften the edges.

4. The metal base was subbed out because tube bending is a process that requires specialized equipment.

5. The hollow stainless steel tubes are cut to the specs that were given to the shop.

6. Once that is done the tubes are formed into a basic circular shape on a hydraulic roll bender. The diameter is set manually, and the process is quick. The tube is fed through a series of three rings that literally "roll" it into a semi-circle (figure B).

7. For the more complex angled curves needed to form the base, the tubes need to go to a different machine called a CNC mandrel draw bender. CNC means computer numerical controlled. Someone inputs the data and the machine does the rest. But what actually moves the metal is a mandrel or internal axle that clamps the piece and forces it to a precise angle.

8. The tubes need to be welded together. The work pieces are clamped to a grounding cable on the work table. The pieces are welded together using a TIG welder. TIG stands for tungsten inert gas and the TIG welder generates heat from an electric arc between the electrode at the tip of the torch and the metal part that is being welded. The electrode is made from tungsten. Tungsten is the same material in light bulbs, but instead of creating light, it's creating heat--enough heat to melt metal.

9. The last step is to attach it to the ottoman.

10. Line up the steel tube base and mark the pilot holes with an awl. Use a handheld power drill and make the pilot holes.

11. Join the two pieces together with screws.

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