DIY Network

Web Extra: Making a Template and Working with Epoxy Amy shows you how to make a template and how to work with epoxy. From "Freeform Furniture" episode DFFF-202

Host Amy Devers demonstrates how to make a template and how to work with epoxy.

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Amy shares tips on creating a template.

Making a Template

• Templates are specific to what you are building. Therefore, each template will be different.

• The medium density fiberboard (MDF) template helps to cut windows out of the top and bottom pieces of plywood.

• For this specific template, cut the MDF to the same size as the table top.

• Next, draw a rectangle on the MDF the same size as the desired window.

• Use a jigsaw to cut it out.

• Drill a hole in the window area of the MDF to put the blade of the jigsaw in to start the cutting.

• Double stick tape straight edge boards along the lines of the rectangle to clean up the jigsaw marks on the router with the flush trim bit.

Note: The trimming bit has a bearing on the top that follows the contour of the template and cleans up the top and bottom inside edges.

Amy also shares tips on working with epoxy.

Working with Epoxy

• Epoxy is a two-step polymer resin that dries hard and clear. Epoxy will adhere virtually any two surfaces together. It is important to use it in a well-ventilated area and to wear gloves and a respirator.

• To use epoxy 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 and makes the mixture cure hard. Failure to measure equal amounts will result in a soft and sticky product.

• Stir the mixture for two minutes allowing the chemicals to react.

• Next, carefully pour the epoxy over the project.

• The instructions for the type of epoxy used on Freeform Furniture recommend mixing no more than six ounces for each pour. Therefore, it may be necessary to make multiple batches.

• Spread the epoxy out evenly over the project. The resin is self-leveling and needs 24 hours to harden and 72 hours to become solid.

• Next, tip the edge of the tray gently so that the resin settles into place.

• Use a heat gun to speed up the elimination process of air bubbles. If you don't help the air bubbles escape, they could get trapped in the epoxy disrupting the clear casting.

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