DIY Network

Nesting Tables: Making the Table Ribs From "Freeform Furniture" episode DFFF-101

Host Amy Devers constructs the lightweight framework for the bent wood table with plywood ribs and spacers.

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	Host Amy Devers begins the first step in making a bent wood table for this set of nesting tables ...
	by making the ribs for the wooden nesting table.

Materials --

2 sheets of 4" x 8" plywood
Pencil
Tape measure
Yellow glue
Drywall screws
2 sheets of 1/8" thick Italian bending plywood
Wood filler
One 4" x 8" sheet of paper-backed Wenge veneer
Scissors
Band clamps
White glue
Low-tack blue tape
Wooden cauls
Double stick tape
180-grit sandpaper
320-grit sandpaper
Wipe on polyurethane
Rags

Tools --

Jigsaw
Router
Flush trim router bit
Table saw
Miter saw
Hand planer
Orbital sander
Vacuum press
Roller

	Figure A
	Figure B
	Figure C
	Figure D

Making the Table Ribs

1. In order to make the ribs all exactly the same size, you need to make a template out of plywood. Size the template so that there will be a comfortable amount of clearance between the acrylic tables. Trace the outline of the rib onto a piece of plywood. In order to get the most ribs out of one sheet of plywood, flip the template so that the ribs interlock (figure A).

2. Using a jigsaw, cut out all seven of the ribs about 1/8" proud of the line (figure B).

   Note: The term proud means to cut a little oversized.

3. Once all the ribs are cut out, screw each one to the original template.

4. Flush trim each one to size on the router table. The router trimmer bit has a bearing on the top that follows the contour of the template and cuts off the excess material from the rib (figure C).

5. With the ribs trimmed to size, cut the plywood spacers that hold the ribs together.

6. Rip the plywood to the proper width on the table saw, and cut the spacers 2" x 2" on the miter saw.

   Tip: A stock block will make cutting the spacers much easier -- you won't have to measure for each cut.

7. Before assembling the ribs and the spacers there are two strips of plywood that serve as the "feet" of the end table (figure D). And like the spacers, cut them to width and length on the table saw.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.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

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Vacuum Bag
Vacuum Pressing Systems, Inc.
553 River Rd.
Brunswick, ME 04011

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Woodcraft
Website: www.woodcraft.com

GUESTS :

Eric Diaz
Acrylic Fabricator
Phone: 310-990-8101