DIY Network

Ottoman Web Extra: Working With Molds and Cork From "Freeform Furniture" episode DFFF-206

Host Amy Devers demonstrates how to work with molds and cork when creating innovative freeform furniture.

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Amy demonstrates how to create wood molds.

Working with Molds

• To make a mold like the one on Freeform Furniture, start with a pre-fabricated plywood cylinder. They come in different sizes and you can get them at a specialty plywood distributor for around $80 dollars.

• If the plywood cylinder is too large for the mold you are making, cut it to size on the table saw. Set the fence to the proper dimension and hold the plywood tube against the fence and roll it over the saw blade to cut it to size.

• Split the plywood into two pieces so it can be easily separated from the form inside. To do this, use a combination square to mark the first cut line. Use a straight edge ruler to mark the opposite side. Use the combination square again to draw the cut line. Use a hand clamp to secure the piece to the work table. Next, use the jigsaw to slice the cylinder in half. The two resulting pieces will be used as the sides of the mold.

• Next, make a bottom cap and a top cap using 3/4" shop-grade plywood. The bottom cap is going to be a circle with about an inch and a half of overhang all the way around. It's a solid piece so that you can screw in both parts of the mold down to and it will hold them together. The top cap fits inside the mold and it will have a handle on it to press down the cork granules as tightly as possible using clamps.

• To cut the circle for the bottom cap, use a router and a circle jig which operates by spinning the router around on a central pivot point. Pilot a hole for the central pivot point. To do that, take a straightedge ruler and make two lines to find the center point for the pivot. Then, drill a 1/2" pilot hole for the pivot point on the router jig. The hand clamp will keep the wood secured while making the circle. Next, insert the pivot of the jig. The jig is just a device that holds the piece and helps guides the tools. This jig has a hand-held router attached to it that guides the router in a perfect circle.

• There are several pieces used to construct the mold, but all of them are made using the same technique. The top cap has a handle attached to push it down into the mold. Another piece, with one straight edge, gets cast into the underside of the cork form. That provides a wooden mounting plate and something to screw the steel base into. Another full circle is used for the indent in the top of the cork form. This piece gets built into the shape of the mold. Before building it into the mold, it needs a round over on the edge. Line up the laminate trimmer to the edge and shave off the excess with the round over bit until it's nice and smooth.

• With all of the parts cut for the mold, the next step is to assemble it. Cut some braces out of scrap wood to attach to the ends of the semi-circles. Also cut mounting blocks to be placed around the perimeter of the cylinder. Use two spring clamps to secure the brace to the wood and a hand clamp to secure it all to the table.

• Then with a power drill, screw on the braces to both pieces of the cylinder. Use the same technique for the mounting blocks. Screw them all into place so that they're flush with the bottom of the mold.

• Next adhere strips of clear packing tape across each section of the mold. Then take a scrap piece of wood to smooth out any discernible creases in the tape.

• Don't put any tape on the wooden mounting plate because it will be glued up inside the cork form. Take the combination square and a pen, make some guide marks, position the wooden mounting block on the lid there so that the hole is facing down, then clamp it in place, flip it over, and drive in some screws. The mounting plate will actually become the bottom of the ottoman.

• Then attach the full circle to the bottom of the mold. This will create the indentation in the top of the ottoman. Later, this will be flipped over to form the top of the ottoman.

• Using the lid to ensure correct spacing, clamp the two half-cylinders together and wrap a band clamp around it to hold them firmly together. A band clamp is a cinching device with a flexible cotton band that's perfect for gripping work pieces like this. Finally, to complete the mold, remove the lid and screw the bottom piece of the mold to the mounting blocks.

• A coat of wax inside the mold will ensure a slippery surface so that the contents of the mold can be easily removed.

Amy shares details on working with cork when creating freeform furniture.

Using Cork

Cork comes from the lightweight elastic bark of the cork oak tree which is harvested about every 10 years. It is then processed into granules or sheets to get it to the familiar form we know today. During the manufacturing process, all raw materials are consumed, either for the finished flooring product or as an energy source. Cork waste such as cork dust and cork tree trimmings are used as fuel to bake the cork tiles in furnaces. Cork provides a nice natural material for consumer use and also helps conserve our natural resources.

Cork is not only environmentally sensitive, but it is easy to take care of and functional. It can be purchased with factory applied polyurethane or wax finishes which are extremely durable and resistant to scratches and gouges. Polyurethane is an extremely durable surface. Wax is also a very durable finish; however, it does require some maintenance such as the application of paste wax and occasional buffing. Paste wax should typically be applied every 12 months for proper care.
Even with polyurethane and wax finishes, cork can wear if not properly cared for and both waxed and polyurethane finished tiles can be refinished many times during the life of the floor.

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