Photos of a recent project that’s a bit out of the norm for me as I usually don’t get a chance to build anything this small. Foyer hallway mirror and ledge. Birdseye veneer with walnut accents. Ledge supports cross over, twist 180 degrees and curve at the same time. It turned out to be one of these rare projects where the client said surprise me just build something unique. The frame & ledge is matching birdseye veneer. Ledge supports are laminated from 7 plies of walnut just a fuzz over 1/16 inch thick.
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Nice. Not sure I'm crazy about the look of the ledge support, but it is executed very well. Did you do this as a stacked lamination over a form with clamps or a vacuum press?
I probably would have used something more elegant than the L brackets though most people would never see it.
have you ever tried veneering over aluminum sheet.
Edited 3/24/2007 8:33 pm ET by TomW
(I probably would have used something more elegant than the L brackets though most people would never see it.}Your right about the L-brackets lacking class however since I had a $700 budget for the entire project including a 500 mile round trip install I didn't think it was wise to spend a lot of time on something no one but the cat can see. The laminations consist of a stacked free form using spring clamps (see photos).The form is pretty basic. Full scale layout on 3/4 plywood. The vertical piece of plywood represents the ledge while the flat section represents the wall. The spacer in the middle suspends the laminates at the right height. The twist causes the curve to naturally flow out.Normally I would use a vacuum bag but I don't have one small enough. The stretch wrap holds the plies in line and for something like this the spring clamps exert plenty of pressure to produce an invisible joint.I have never tried the aluminum sheet you mentioned. What would be the advantage?
So many nice things in a clean, organized area! Could you post more pics of your shop, please??
I have never tried the aluminum sheet you mentioned. What would be the advantage?
I'm veneering some aluminu, guage panels for a friend and I'm not sure what glue wold be the best application. I am considering epoxy but I know that aluminum does not always bond well with it. If i can find a good solution I have a couple ideas that would be well suited to using aluminum for the substrate. I was hoping you may have had some experience with it.
Again nice work and I understand about the L brackets. Those darn budgets are always limiting the creativity.
One trick I've heard of for epoxying to aluminum is to first wet the aluminum with epoxy, and then wet sand it. That exposes pure aluminum to the epoxy, but not to the air, so you shouldn't get the oxide layer.did<!---->Cure Diabetes - Whitefish, Montana, 2007!<!---->
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Not exactly what your planning on doing however years ago we built a series of counters in a corporate office and laminated a skin of brushed aluminum over a curved layer of bending plywood. We used contact cement, it worked very well however the laminations were not structural so there was no stress against the glue line.
Contact cement won't work in this application since there is some marquetry involved. I'm going to experiment with some different epoxies and poly glues and see if I can find a process that is reliable.
Beautiful stuff there..
Uh, don't mind me drooling all over that band saw! I need to get a riser block if they make one for Ridgid, so I can resaw greater than 5.5 " High..I have a lot of cool wood that is just too nice, to not turn into bookmatched veneer.Inmate # 40735 At Taunton Federal Penitentiary.
There is a riser block kit for the Ridgid saws - it also comes with the extended blade guard and, believe it or not, a pretty decent blade. (The standard lenght blade that comes with the saw is a piece of crap)One thing that greatly improved the rigidity of my Rigid saw was to mount a piece of 3/4" plywood in between the saw and the metal stand - that eliminated a huge amount of vibration at startup. Also installed a link belt which probably didn't hurt as well.JT
Thats nice to know. A shame I have so many blades at 93.5". I might need 2 saws..LOL
I also need to put new tires on my saw..basic maintance stuff, I keep putting off.Inmate # 40735 At Taunton Federal Penitentiary.
Excellent work.
One can never have enough clamps. Do you rip the walnut on a table saw or resaw on a band saw? Are the rips indexed?
Chuck Slive, work, build, ...better with wood
Thanks Chuck, These strips were small enough to rip on the table saw, they were indexed to match the grain as much as possible. I can't stress enough the advantage of stretch wrapping the stack of laminates prior to bending. We used to fight long handrail laminates from shifting while bending into position around the form. The stretch wrapping only takes a few minutes, has just enough give to allow the plys to slip lengthwise while still maintaining the intended cross sectional shape.
Stretch wrap. Who woulda thought. I need to keep that one in mind. Thanks.
Another use for stretch wrap! Definately will use that tip. Thanx
Chuck Slive, work, build, ...better with wood
First of all, beautiful work. Forgive my ignorance, but what is 'stretch wrap?' Also, what type of glue did you use? In the past, when bending up laminations, I have used a watered down carpender's glue, but it seems like that would be messy to apply glue, then wrap and clamp.
Thanks buddy, as to your questions:See photo of stretch wrap. I'm sure you have seen the stuff everywhere.I use Unibond 800 it a two part resin powder catalyst adhesive. It the best glue out there for laminations since there is virtually no cold creep of the glue line. It's the only glue I ever use for stressed laminations.Mess: There is none. I can usually glue up a 16 ft handrail and maybe get a bit of glue on my finger tips.The stretch wrap contains the glue squeeze out. Once the glue sets and the stretch wrap is removed the surface may have a thin surface film of glue much like a light coat of varnish. It sands off very easily unlike yellow glue which creates a gummy mess while sanding.
Armin,
I have used recorcinal glue for 30 years.
Is Unibond 800 similar?
Lots of doors and windows in Lewes DE.
Chuck Slive, work, build, ...better with wood
(I have used resorcinol glue for 30 years.Is Unibond 800 similar?)I think it is similar although I don't seem to remember the Resorcinol applying or sanding as easily as the Unibond.
I like it...Husband is going to build a small shelf in our hallway...I was thinking rosewood with maple...
Edited 3/24/2007 8:35 pm ET by Carole4
Thanks Carole. The rosewood and maple would make a nice combination.
Armin
Very nice! Very elegant, I like the contrast in your wood choice. As always, a pleasure seeing your work.
Are your bent lam's really holding that shelf up? or do you have some sort of torsion box going?
Hell, I dont mind the L brackets although I do notice the cat starring at them, maybe just trying to figure out how you made the curves!
Doug
Doug,The brackets support the weight nicely. I wanted to see what they might hold so I loaded a tad over 100 lbs of books on it still looked good so I assumed it might carry the cat as well.In retrospect I should have taken a photo of the supports before they were installed, they look like a big wishbone.
Wow- that's great. I was expecting a much more complicated jig for those supports. How did you figure the curve/twist to be what you wanted?
Haven't seen you around BT for a while, I was starting to wonder. . . .
zak
"When we build, let us think that we build forever. Let it not be for present delight nor for present use alone." --John Ruskin
"so it goes"
Thanks Zak,(How did you figure the curve/twist to be what you wanted?) Basically full scale layout, take a couple of thin strips of wood clamp them in place as see how it looks.(Haven't seen you around BT for a while, I was starting to wonder. . . ).In other words you were wondering if the mother ship beamed me up yet. Still here, bending nails and making sawdust.
Beautiful, Armin. I love the combo of birdseye and walnut. They got a heck of a deal for the price.
"War is God's way of teaching Americans geography." Ambrose Bierce
Thanks Crash,(They got a heck of a deal for the price.)Yes they did but then I built two staircases for them as well as office cabinets. Currently working on a mantel and a china cabinet. Really great clients so I gave them a deal besides the lady is very pretty with a personality to match.
That is awesome. So simple but so interesting.Is the slate on the floor installed with no grout joints?
Very elegant design. That is really beautiful work.