DIY Network

Cutting the Acrylic Host Amy Devers demonstrates how to cut the acrylic for the table lamp. From "Freeform Furniture" episode DFFF-210

The second phase of this unique Freeform Furniture table-lamp projects involves the cutting of acrylic, using the same process for cutting the tempered hardboard template previously. Amy Devers cleans the edges on the router and uses the drill press to drill holes through the acrylic.

Don't forget to smooth the edges of the acrylic pieces with a power sander.

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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.
	Amy Devers continues the table lamp project by cutting the acrylic—instructions at left.

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
hand-held screw driver

	Figure A
	Figure B

Cutting the Acrylic for the Lamp Table

1. With the blade of the band saw set, cut the first piece of acrylic using exactly the same process that you used to cut the tempered hardboard template (figure A).

2. Repeat the same cuts for the remaining three sides of the table. Next, cut out the tabs.

3. Clean up; the rough edges using your template and a flush trim bit on the router table.

4. Begin to attach the template and the roughed out acrylic side of the table together using double stick tape.

5. Use a flush trim bit to clean up the acrylic's rough edges. The router bit has a bearing on the top that follows the template and cut off the unwanted material (figure B).

6. Flush trim the three remaining sides of the table the same way.

7. Using a round over bit, carefully go over the sides of the acrylic.

8. Make the marks for the holes you are going to drill on the bottoms of each of the four acrylic side pieces.

9. Clamp the first side piece in place.

10. When drilling holes through acrylic, you get the best results with a drill press.

11. Smooth the edges with a power sander, using sandpaper specifically designed for finishing acrylic. It is important to spray a little water on the edges while sanding to achieve a smoother finish.

12. For the tight spots, use a sanding disc and do it by hand.

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