DIY Network

Creating the Frame of the Lamp Table Host Amy Devers constructs the frame of the table lamp. From "Freeform Furniture" episode DFFF-210

Host Amy Devers continues the lamp-table project by removing the protective paper from the acrylic and placing the tabs on top of the strip heater. She uses a forming jib to assure the bends are accurate and consistent throughout. She then cleans the acrylic and clamps it so it is square to the jig.

Lastly, she lines up the pieces, removes the backing on the tape and joins the tables together.

advertisement

	Room: Before
	Room: After
	Amy Devers has created an out-of-the-box table lamp that will highlight—and brighten—any room.
	Amy Devers puts together the frame of the table 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
hand-held screw driver

	Figure A
	Figure B

Constructing the Frame of the Table Lamp

1. Remove the protective paper from the acrylic (figure A).

2. Place the tabs on top of the strip heater (figure B). Heat the tab until it begins to sag at the bend line. It takes about five minutes for the acrylic to become pliable.

3. Turn the acrylic over and heat the other side of the tab. Allow the material to heat thoroughly until it softens or welts in the area to be formed.

4. While the tables are heating up, set up the forming jig. The forming jig is made up of two pieces of wood with 45-degree angles attached to a piece of plywood.

5. Keep the heated side of the acrylic on the outside of the bend.

6. Clamp the acrylic in place until it cools.

7. Remove the acrylic from the jig. Repeat the heating and bending process on all the tabs for the four side pieces of the table.

8. Use a soft, clean cloth and clean any dirt or dust off of the acrylic.

9. Make sure the very high bond (VHB) tape spans the length of each tab for maximum strength.

10. Using a jig to help everything get lined up so it sits nice and flush and flat on the floor. When you get everything lined up the way you want it, peel the tape and stick the parts together.

11. Clamp the acrylic so it is square to the jig. Next, line up one of the side pieces, remove the backing on the tape, and join the tabs together.

12. With the pieces together, reposition the table frame.

13. Join another side of the table.

14. To guarantee a strong bond, apply heavy pressure to the tabs as the frame of the table comes together.

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