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

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	Figure C
	Figure D

3. Line the edge of the perforation up with the edge of the tube and clamp the whole assembly to the table. Using a scrap of wood as a caul (figure C) will help to distribute even pressure while clamping. Use several clamps to squeeze the tab up against the tube forming a 90-degree bend.

4. Reposition the flat panel and line up the next perforation for the next fold.

5. For the next fold you can bend most of the way manually before finishing it off with a caul and clamps.

6. Spin the steel around and repeat the process on the last two folds. This is the time to examine the bends and make adjustments if necessary to make sure the box is square.

7. To make the connection, run a strip of VHB tape along the tab (figure D) and press it firmly in place. After removing the backing paper, slide the tab under the bottom of the box and add a little pressure in the form of clamps and a block of wood.

8. Take the clamp off and get ready to install the shelf using two square rods as shelf brackets and the VHB tape.

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	Figure E
	Figure F

9. Bend the tab to make lips on the shelf.

10. Bending the shelf happens exactly like bending the box. Sandwich the steel between the square tubes, line up the perforation, clamp it in place, and bend it with clamps and a caul.

11. Apply strip of VHB tape to the shelf supports and position them inside the box using a spacer block (figure E).

12. Put some VHB tape along the top of the brackets, peel the paper, and put the shelf in place.

13. Use a textile based wall covering to cover the outside of the box because it is resilient, it repels moisture, and it is easily cleaned. It is made from reclaimed materials so it is eco-friendly as well. To apply the wall covering, use a multi-purpose spray adhesive (available at hardware stores).

14. Protect the inside of the box from overspray. You can make a panel by laying out the material and cutting a little oversized using a razor knife. Lay it over the top without any glue to make sure it fits properly.

Safety Tip: Use a respirator when applying the adhesive.

15. Spray the adhesive onto the steel box making sure to get even coverage on the entire surface.

16. Let the glue set up for about 30 seconds and then lay the wallpaper on the box.

Note: Be care to apply it right the first time, because it will bond on contact.

17. As you lay down the textile, work out any air bubbles and imperfections with a plastic wallpaper smoothing tool (figure F). You can burnish this with any number of tools--a hard roller or even a smooth strip of wood.

18. Using a razor knife, trim off the excess wallpaper.

19. Fold up the tabs.

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RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.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

Waterjet Services
Flow International Corp.
Website: www.flowcorp.com

Greek Marble, Inc.
Phone: 323-221-6624

Forrest Manufacturing Company
Website: www.forrestblades.com

Wolf-Gordon, Inc.
Website: www.wolf-gordon.com

GUESTS :

Jeff Bailey
Flow International Corp.
Website: www.flowcorp.com