WoodNet Forums: 2 x 6 contest: The curvy table (MANY pix)

The table, done - please, vote with your heart

It all started with a small sketch on the proverbial napkin, Sandy and I talking about "...the little table I am itching to make...":

Then, as part of a learning exercise, I transferred the sketch to SketchUp:

I bought a 2" x 6" x 8-foot board at the local Lowes (less than $4, and guaranteed to produce excellent results...

) - chalk layout confirmed plenty of lumber to make the table:

I weighed my options to make the curves: make a mold, or use the vacuum bag. I elected to make the mold, as the leg pieces would be very narrow, and difficult to handle in the bag.

Step 1 of making the mold: Make a full-size drawing:

Laying out the curves for the full-size drawing was interesting - but I found an easy way to zero in on the trammel length I would need. First, large calipers, to get the curves to look "right":

Then I made a simple trammel with a hole large enough to allow the pencil tip draw two lines, the rough outline of the leg and stretcher thickness:

Using the trammel, I drew the curves on a piece of 1/2" thick MDF, and cut the curve on the band saw:

Before continuing, it was necessary to smooth the edges, to finish the MDF boards with these "master" curves - I made a flexible sanding block, and sanded until happy with the curvature:

After transferring the smooth outlines to 3/4" MDF, I cut close to the line, and used a pattern router bit to make exact duplicates of the "master" curves:

It took several copies to make the mold to create the curves, but I was finally ready to use the mold - here is one-half of the mold, as I prepare to apply cork and tape over the cork - each new piece is screwed on to the previous one, to keep all pieces perfectly aligned:

NOW I was ready to resaw the pieces for the legs:

The leg pieces ready, I start applying glue:

And the resawn pieces go into the mold, 3 thicknesses per leg (after smoothing a bit at the drum sander):

The last set of legs out of the mold - it will require cleaning of the edges, and cutting to width:

After cleaning one edge, the other edge is best "cleaned" on the band saw, to remove the bulk of the dry glue:

The greatest challenge was making the bevel on the long stretchers, to provide a pleasing angle, and sufficient surface area for the glue line (the curve did not allow a true scarf joint) - 5-minute epoxy was my friend this time, as it is an impossible joint to clamp without resorting to the use of fasteners:

While the top was in the clamps on glue-up, I cleaned the edges of the legs using a block plane:

Resawing the long part of the 8-foot board was actually the easiest part of the entire process. At 7/16" thick, and a 45° bevel on the bottom of the edges, it gives the table a lighter appearance.

I now introduce the finished table with the curvy legs:

Thanks for reading, and following along.

Al

P.S. - Edit to add: I now consider this table a "prototype"

- thus, no finish.

Edited by Sandal Woods (06/17/10 05:26 AM)