DIY Network

Nesting Tables: Skeleton Assembled and Covered with Plywood From "Freeform Furniture" episode DFFF-101

In this segment host Amy Devers assembles the skeleton and covers it with plywood.

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Host Amy Devers creates the skeleton for the nesting table and covers it with bendable plywood.

Materials --

2 sheets of 4" x 8" plywood
Pencil
Tape measure
Yellow glue
Dry wall 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
220-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
	Figure E
	Figure F
	Figure G

Skeleton Assembled and Covered with Plywood

1. The first step is to take one of the ribs and attach six spacers. Clamp in the first rib and pre-mark where the spacers will go (figure A).

   Note: The skeleton will have seven ribs, 33 spacers which are staggered, and two feet.

2. For each spacer run a bit of glue on the edge of each spacer and line them up where you have placed the marks.

3. Make a pilot hole in each spacer (figure B).

4. Drive a screw through the rib and into the spacers. Repeat this process for all of the spacers on each rib.

5. After the spacers are attached to the second rib, line it up with the first rib and then screw them together (figure C). For the second rib attach five spacers to create the stagger. Continue this process until all seven ribs are fastened together.

6. With the skeleton assembled flip over the table and put glue on the bottom edges of each rib and screw the feet onto each side.

7. To cover up the guts of the table, the top and underneath is covered with a thin piece of 1/8" thick Italian bending plywood, which is made to conform to curves and bends.

   Note: Italian bending plywood comes in 4' x 8' sheets like regular plywood, and it costs about $15 to $20 a sheet. You can find it at most specialty hardwood stores.

8. Cut the piece of bending plywood slightly oversized. Set the skeleton on blocks, and then the first step is to run a bit of glue on the tops of all the ribs and center the bending plywood over the ribs. A good tip is to mark the centerline on the plywood and a centerline on the framework and then match them up (figure D).

9. Staple the bending plywood to the center rib with a staple gun using 5/8" staples. Use a scrap piece of wood that is marked every 2" to line up with the ribs underneath -- this helps to hit the ribs and not dead space.

10. Bend the plywood over the radius of the skeleton (figure E) while at the same time applying pressure to assure a tight fit. As you work the plywood into place, staple it about every 2".

11. After the top piece of bending plywood is stapled in place, lay the table on top and glue everything up. Attach the other sheet of bending plywood to the inside surface and again using the stapling gun attach the ribs every 2" (figure F).

12. Because the bending plywood was cut slightly oversize, the edges need to be flush with the skeleton underneath. To do this, use a laminate trimmer which is basically a router, but it is only used for flush trimming material. The laminate trimmer is used most often to trim laminate -- hence, the name. It has a cutting bit with a bearing head that guides the cutting blades along the skeleton (figure G).

13. Since the base of the trimmer is too wide to cut the inside corners, file down those sections and then use a small block plane to smooth out the edges.

14. After the frame work has been completely skinned with the bending plywood it is almost ready for veneer. Fill in all the staple holes with wood filler so that the surface is smooth. If there are any imperfections at this stage, they will telegraph through the veneer and will be just about impossible to get rid of later.

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