DIY Network

End Table Glass Insert Amy creates the end table glass insert from broken auto window glass. From "Freeform Furniture" episode DFFF-202

Host Amy Devers makes the glass insert for Arthur's end table by using broken automobile window glass suspended in place with a clear epoxy resin, and she caps it off with a sheet of solid glass.

To cast the broken glass in epoxy, she uses a plywood tray. Inside, she places a sheet of glass--the broken glass--and then pours the epoxy into the form.

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	Amy creates a modernistic glass insert using broken automobile glass.
	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

The Glass Insert

1. To make the glass insert, you will use broken automobile window glass that you will suspend in place with a clear epoxy resin and cap off with a sheet of solid glass. Use a 1/18" sheet of glass and have a local glass dealer cut the glass for you and seam the edges so that you won't cut yourself.

2. Tape around the edge of the pane of glass. The packing tape acts as a barrier between the epoxy and the tray and ensures that the glass won't stick in the mold.

3. Clean off the surface with a glass cleaner and paper towels removing all finger prints and dust particles. Because you will be pouring a permanent layer of epoxy on top of the glass, the prints would be noticeable forever if not removed.

4. Once the pane of glass is cleaned, set it inside the mold and seal the tape in place (figure A).

5. It is time now for the broken auto glass. To create a neat pattern, use all different shapes of broken glass. Simply arrange the broken auto glass in an abstract pattern until the majority of the surface is covered (figure B).

6. Once the glass is in position and broken glass arranged the way you want it, it is time to suspend it all in place using clear epoxy.

   Note: Epoxy is a two-step polymer resin that dries heard and crystal clear. It adheres pretty much will adhere any two surfaces together. It is great for casting three dimensional objects. It is pretty easy to work with, but it is important to use in a well ventilated area. Be sure and wear gloves and a respirator.

7. Carefully measure equal amounts of resin and catalyst into a wax free measuring container. Catalyst is a liquid that increases the rate of the chemical reactions which makes the mixture cure hard. Failure to measure equal amounts will result in a soft and sticky casting.

8. Stir the mixture for two minutes to make sure the chemicals are thoroughly mixed.

9. Pour the epoxy over the auto glass being careful not to disturb the arrangement (figure C).

10. To completely cover the glass, mix another batch of epoxy. Follow the instructions recommended for how many ounces to mix for each pour.

11. Pour the second layer and spread it out evenly until all the glass is covered. The resin is self leveling and needs 24 hours to harden and 72 hours to fully cure.

12. Tip the edge of the tray gently so that the resin settles in place.

13. Use a heat gun to speed up the elimination process of the air bubbles (figure D). If you don't help the air bubbles escape they could get trapped in the epoxy.

    Tip: A hair dryer will work as a heat gun alternative.

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