DIY Network

Molding the End Table Glass Amy covers the plywood and molds the glass for the end table. From "Freeform Furniture" episode DFFF-202

Host Amy Devers uses a self-leveling underlayment to cover the plywood. She mixes and applies the cement finish with a trowel. She then sands the piece and applies a spray-on lacquer, which helps seal and protects the cement.

Amy then assembles a plywood form to help mold the glass, shattered glass and epoxy.

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	Amy applies cement to plywood in order to create a unique frame for the end table.
	Before: Arthur wasn't too particular about where he placed his reading materials before Amy created...
	this unique, urban end table created with plywood, cement and broken automobile glass.

Materials:

birch plywood
plastic push stick
medium density fiberboard
double-stick tape
straight edge boards
pencil
220-grit sandpaper
low tack masking tape
flat latex house paint
white wood glue
brad nails
cement-based finished underlayment
bucket
spray shellac
respirator
packing tape
screws
sheet of glass
broken automobile glass
epoxy
glass cleaner
paper towels
gloves
wax free measuring container
wooden stick
acetone
spacer strips
blue tape
pre-fabricated steel legs

Tools:

table saw
crosscut sled
jigsaw
router
flush trim bit
cordless drill
clamp
table router
trowel
heat gun
staple gun

	Figure A
	Figure B
	Figure C
	Figure D

Applying Cement to Plywood

1. Self leveling underlayment is used. It is the type of thing that is typically used to level out subfloors and is formulated to go directly onto plywood.

2. To begin the cement mixing process, use two parts cement-based finishing and underlayment to one part water. Mix two to three minutes creating a smooth lump-free consistency. The cement finish has 15 to 20 minutes of work life before it hardens so it is important to work fast while still maintaining accuracy.

3. To begin the application scoop the cement-based finish onto the apron and work it into place with a trowel (figure A). Smooth out the cement mixture adding sufficient pressure to get a strong bond to the plywood. Pack the finish firmly on the plywood sides to remove any air bubbles and to fill any minor imperfections in the wood.

4. By just skim coating the plywood, you have more control with the trowel to keep the surface smooth and uniform. When the sides are dry you need to mix up a new batch to do the top. It is much easier if you clean it off when it is wet and let it dry and then come back and do the top.

5. Repeat the troweling process and smoothing out the cement finish covering the entire plywood table top (figure B). With the surface covered, allow 24 hours of dry time before you handle the piece.

6. It will probably be a little rough so you can smooth it out and give it a little more polished look by hand sanding with 220-grit sandpaper. Apply medium pressure being careful not to sand through the thin surface.

7. After it is sanded, apply a spray lacquer which helps to seal and protect the cement.

   Safety Tip: Wear a respirator (figure C) and work in a well-ventilated area when applying lacquer.

8. Let the lacquer dry approximately half an hour before handling the piece.

9. You need to make a plywood form to help mold the glass, shattered glass and epoxy. Use the same 1/2" birch. In order to make the right size for the end table, it is going to be about 14" x 16".

10. Cut the parts on a table saw. Start by cutting the frames and the ledger strips for the form to width on the table saw. The ledger strips will hold the glass in place.

11. Use a cross cut sled to cut the pieces to length for the form. The sled helps to support the wood as you push it through the blade.

12. With the parts cut, line the inside of the form and ledger strips with packing tape. Packing tape is super slick and that is critical for the next step. When you pour the epoxy for the glass top and it cures, the packing tape ensures nothing sticks to the piece, so you should be able to easily remove it from the mold.

13. To attach the parts for the form, drill pilot holes through the ledger strips and into the side pieces (figure D). Finally, to wrap up the form for the glass table top, screw the frame together.

14. Put a pane of glass in the form just to make sure you have the size right.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

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

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.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

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

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

Lie-Nielsen Tookworks, Inc.
Website: www.lie-nielson.com

Wilsonart Laminate
Website: www.wilsonart.com

MacBeath Hardwood
Website: www.macbeath.com