DIY Network

Acrylic Pieces Learn how to make the table-lamp template for cutting acrylic pieces. From "Freeform Furniture" episode DFFF-210

Host Amy Devers makes a template for the acrylic pieces of the table lamp. Then she cuts the acrylic pieces on the table saw. Lastly, she traces the hourglass shape onto the paper protecting the acrylic pieces.

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	Room: Before
	Room: After
	Amy Devers has created an out-of-the-box table lamp that will highlight—and brighten—any room.
	The table-lamp project begins by designing the shape for the lamp.

Materials:

tempered hardboard
spray glue
paper
acrylic sheets
marker
flush trim bit
double stick tape
plywood
sanding disc
heat strip
very high bond (VHB) tape
light bulb
porcelain socket
lamp wire with pre-molded plug
floor dimmer switch
frosted acrylic cylinder
3/4" plywood
straightedge ruler
pencil
spray on primer
respirator
spray paint
feet
screws

Tools:

band saw
hand file
table saw
router
round over bit
drill press
clamps
power sander
forming jig
cordless drill
drill bit
circle cutting router jig
disc sander
electric screw driver

	Figure A
	Figure B

Acrylic Pieces for the Table Lamp

1. You need to make a template so that all four sides end up being exactly the same. Do a full scale drawing of the precise shape you want on the acrylic.

2. Spray an even coat of the spray glue onto the tempered hardboard. This will make it easy to mount the drawing flat.

3. Line up the end of the drawing with the tempered hardboard and press the paper in place.

4. Cut the template using the band saw. To make the cutting process easier, make access cuts. The access cuts help the blade move fluidly through the wood (figure A). Reposition the template and saw through the access cuts.

5. For the other side of the template, repeat the same cutting process. First, make the access cuts, and then saw through them.

6. Cut the four tabs on the template.

7. With the template cut to size, use a hand file to clean up the rough edges.

8. Take the acrylic over to the table saw and cut out the exact sizes you need for the table top and the table sides.

9. Set the fence to the right dimension for the table top.

10. Set the blade on the table saw to clear the thickness of the acrylic by at least an inch.

11. Reset the fence for the side pieces to cut them to length. As you guide the acrylic through the carbide tipped blade always make sure to keep it square to the fence.

12. Reset the fence again and cut the four identical sides of the table to width.

13. With the template lines up, use a marker and trace the hourglass shape onto the paper protecting acrylic (figure B). Do the same tracing process for the remaining three sides of the table.

RESOURCES :

Festool
Website: www.festoolusa.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

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

MacBeath Hardwood
Website: www.macbeath.com

IMS Metal
Industrial Metal Supply Company
Website: www.imsmetals.com