DIY Network

Cutting and Assembling the MDF Pieces Work begins on the coffee table top. From "Freeform Furniture" episode DFFF-113

Host Amy Devers traces the template on the medium density fiberboard, cuts it and assembles the pieces. And she then cleans the edges with a router.

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	Amy cuts the MDF and assembles the parts.
	Above is a side view of the finished coffee table.

Materials:

tempered hardboard
framing square
spring clamps
pencil--carpenters and white chalk
ultra light medium density fiberboard (MDF)
brad nails
flat head screws
double stick tape
razor cutter
high pressure laminate
water-based contact adhesive
latex gloves
cotton sponge roller
ruler
masking tape
brown craft paper

Tools:

band saw or hand-held jig
disc sander
band saw
pneumatic nailer
router
laminate trimmer
J-roller
mallet

Figure A

Cutting and Assembling the MDF Pieces

1. Smooth the rough edges of the template on the disc sander. Gently press the fiberboard against the sanding disc and slowly move the template against the direction the belt is moving (figure A).

Note: If you move it the other way, the force of the machine could knock the piece out of your hand.

2. You will make the actual tabletop out of two pieces of the ultra-light MDF. You use two pieces for added thickness to showcase the laminate on the edge.

Note: MDF stands for Medium Density Fiberboard. Like the tempered hardboard that was used to make the template, it is made of compressed wood particles that are compressed with glue and then pressed out in sheets. It comes in standard 4 x 8 foot sheets and costs approximately $25 a sheet at any standard lumber supplier.

3. Put the template on top of each piece of MDF and trace the shape.

4. Once you finish tracing, take the MDF over to the band saw and cut the curves.

Note: Keep a close eye on the edges so the piece is as close to a perfect ellipse as possible.

5. After both pieces of MDF are cut, attach them together before smoothing out the edges.

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