DIY Network

Bending Metal and Installing Shelf The metal for the entertainment unit is bent and the shelf installed. From "Freeform Furniture" episode DFFF-112

Host Amy Devers makes a jig that she uses to bend the metal for the mobile entertainment unit, and then she applies tape to hold it together. She also installs a shelf and covers the entire piece with wallpaper.

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	Host Amy Devers bends the metal and installs a shelf for the mobile entertainment unit.

Materials:

African mahogany
stainless steel sheet
ear protection
safety glasses
tape measure
forstner bit
biscuits--two different sizes
ruler
pencil
clamps
combination square
foaming glue
glue brush
band clamps
damp cloth
vinyl gloves
tung oil
plastic cup
respirator
lint free cloth
400-grit sandpaper
VHB tape
2 heavy duty square tubes
cauls
2 square rods
wallpaper
multi-purpose spray adhesive
wood panels
plastic wallpaper smoothing tool
stainless steel truss head screws
ball casters
small screws

Tools:

water jet cutter
table saw
planer
drill press
biscuit joiner
hand sander
utility knife
screw gun
drill

Bending Metal and Installing Shelf

Note: The front lip corresponds to the tab on the flat panel (figure A). The perforated lines are the corners of the box.

1. To help bend the steel, make a bending jig. It is just two heavy-duty square tubes that you clamp to the edge of the table and along the perforation in the steel (figure B). With a series of clamps and cauls, you can make the bends.

2. Sandwich the flat panel between two lengths of square tubing.

Figure A

Figure B

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