DIY Network

Entry Table: Creating the Leather Tray From "Freeform Furniture" episode DFFF-104

In this third segment host Amy Devers creates the leather tray for the Entry Table.

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	Host Amy Devers shows you a unique way to make a leather tray using a vacuum bag.
	The leather tray is the perfect spot for your keys.

Materials:

Eucalyptus rough lumber
Push block
Measuring device
Safety glasses
Miter gauge
White glue
Trowel
Clamps
Dowels
Combination square
Pencil
Awl
Dowel center points
Masking tape
T-square
Biscuits
Chamfer bit
Cowhide
Wooden form
Bucket
Hot water
Glue brush
Utility knife
Ruler
Template boards
Double stick tape
180-grit sandpaper
220-grit sandpaper
Clean cotton cloth
Rubber gloves
Leather dye
Wipe-on polyurethane
Mallet

Tools:

Jointer
Planer
Table saw
Hammer
Drill press
Biscuit jointer
Vacuum bit
Jigsaw
Router

	Figure A
	Figure B
	Figure C
	Figure D

Creating the Leather Tray

1. You can use a vacuum bag to make the leather tray. The concept of the vacuum bag is simple--take the leather and put it over a form and then put the whole thing in a bag and suck all the air out. The vacuum bag essentially becomes a blister pack over the leather. If you don't have a vacuum bag, you can come up with a two part mold (such as a couple of bowls).

2. Soak the pieces of cowhide for the tray in a bucket of hot water. With the leather wet, it is much more pliable and easier to work with when shaping.

3. Once the leather is fully saturated, put standard white glue on the back of the leather. Next, spread the glue covering the entire surface (figure A) and sandwich the two pieces together making sure the good sides of the leather are facing out.

4. Place the pliable leather for the key tray over the plywood form and stretch the leather out.

5. To begin, put the leather covered form into the vacuum bag, which is basically a vinyl bag that is hooked up to a vacuum pump, then completely seal it and flip on the vacuum. As the vacuum sucks out all the air, the bag tightens against the leather tray. The pressure creates perfect uniformity on the piece. Smooth out the corners to avoid any wrinkles or creases forming in the leather tray (figure B). Because the leather is so wet, let the piece set up overnight.

6. Once the leather has turned back to its original color, unseal the bag and take the leather tray out. Remove the excess leather with a utility knife. Carefully trim the leather edge so it is even all the way around (figure C).

7. Determine the size and shape of the opening in the table top. Take the dimensions off the form and transfer them to the piece.

8. With a ruler measure out the specific dimension to be cut from the table top. To make the cutting easier, take the top to your drill press and make pilot holes.

9. With the table top clamped to the worktable insert your jigsaw blade inside the hole so you can begin to cut (figure D). Rough cut as close to the line as possible making sure to be careful when going around the corners.

10. To clean up the rough edges on the opening for the table top, attach the template boards using double-sided tape to the bottom of the table top. The template board acts as a guide for the router. Flip the piece over, clamp it down and trim the inside edge using a flush trim bit on the router. To finish off the work on the opening for the top, use a router with a chamfer bit to soften the edge to 45 degrees.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Vacuum Pressing System
Website: www.vacupress.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

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

Ulmia GmbH
Website: www.ulmia.de

Lumber
Weyerhaeuser Co.
Website: www.weyerhaeuser.com

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com