DIY Network

Web Extras: Sanding Acrylic and Installing Lights Host Amy Devers demonstrates how to sand acrylic and install table-lamp lights properly. From "Freeform Furniture" episode DFFF-210

Two of the most important steps in creating the unique table lamp in this episode (DFFF-210) of Freeform Furniture were sanding the acrylic pieces and installing the lights inside the table. Amy Devers shares the trick to doing both tasks correctly in this Web-extra content.

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Amy Devers teaches you how to cut acrylic correctly—instructions at left.

Sanding Acrylic

• Acrylic is a type of plastic. You can use standard wood working equipment to machine it including a jigsaw, router, sander and table saw. The acrylic pieces used on Freeform Furniture were covered by a protective film. Leave that on until finished machining the entire piece.

• To finish the edges and take away the hard, crisp edge that the saw leaves behind, attach the template to the piece of acrylic with double-stick tape and use a flush trim bit on the router table. The router has a bearing on the top that follows the template and cuts off the unwanted material. Then, using a round-over bit, go over the sides of the acrylic. The round-over helps to soften the edge and creates a nice detail.

• You can smooth the edges with a power sander using sandpaper specifically designed for finishing acrylic. It's important to spray a little water on the edges while sanding to achieve a smoother finish. For the tight spots, use a sanding disc and do it by hand.

• Finally, remove any protective covering from the finished acrylic.

Instructions for installing a light unit into a lamp table are at left.

Installing a Lighting Unit

• All of the supplies for the light fixture, including a porcelain socket, a bulb, a lamp cord with a pre-molded plug, and a dimmer switch, came from the hardware store. A length of frosted acrylic cylinder works well to diffuse the light from the bare bulb. This acts as a lamp shade for the light bulb and combined with the dimmer switch, gives a nice, warm ambient glow.

• The base of the table is made out of 3.4" inch plywood. First, find the center of the piece of plywood to center the lighting unit. Use a straightedge ruler and draw a line from the corners of the plywood. Because the piece is square the center point is easy to find. It's simply where the two lines intersect. Next line up the drill bit with the center mark.

• Use a circle cutting router jig to cut the groove in the plywood for the acrylic tube. Fit the pivot point on the arm of the circle cutting router jig into the drilled hole. The pivot then guides the cutting bit of the router in a perfect circle. Apply downward pressure guiding the router in a clockwise direction while routing the groove.

• Next, use the disc sander to round the corners of the base. Then apply a spray-on primer. After the primer is dry, apply an even coat of white spray paint. After five minutes of dry time, mark the placement on the bottom of the plywood base for the feet and drill the pilot holes for the screws. The feet will protect the plywood and allow access under the base to feed a power cord for the light source.

• Next, feed the lamp cord through the hole in the base and remove the wire coating.

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