DIY Network

Bent-Laminate Lamp: Bending the Koa-Wood Laminates From "Wood Works" episode WWK-512

The bending form for the laminates is created from three sheets of 3/4-inch plywood that have been cut, stacked and fastened together with screws. The form is then cut into sections to accommodate the extreme curve of the laminates.

With the bending form for the bent-laminate lamp made from plywood, work can begin on creating the center-post for the lamp from Hawaiian koa-wood. In this segment, the laminates for the center-post are cut, glued and placed in the bending form.

Materials:

Table saw
Band saw
Jointer
Power planer
Drum sander
Band saw
Belt-sander
Straight-edge
Carpenter's pencil
Carpenter's tape
Slow-setting resin glue
Glue roller
Clamps
Safety glasses or goggles

Safety Alert: Always wear safety goggles or safety glasses when
working with wood, power-tools, saws, drills, routers, etc.

advertisement

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Laminated Center-Post

• To create the laminates for the center-post, begin with 4-quarter koa stock that's been milled to jointed, planed and ripped to 4-1/2 inches wide and 74 inches long. The extra length will allow for the bend and for slippage.

  Tip: Because the center-post will be thick, several pieces of stock will need to be used for creating the laminates. As you pick out your stock, be sure to look for pieces that are similar in color in order to create the illusion that the curved post is sculpted from a single piece of wood.

• Depending on the final thickness of each laminate, you can expect to cut between 19 and 24 individual laminates from the koa stock to build a stack that's 1-1/2 inches thick. We cut each of our pieces stock wide enough to make two laminates to save time in cutting.

• Carefully cut each strip 3/32-inch thick at the band saw. For added safety, use a finger-board to hold the stock against the fence (figure A), maintaining even pressure while protecting your fingers.

• Run each strip through the drum sander (figure B) to remove any saw-marks and to make them all a uniform thickness. Each laminate needs to be thin enough to take the extreme curve without cracking. We milled each of our strips to a thickness 1/16-inch. The moisture from the glue, once added, helps make the wood flexible enough to take the bend.

• Once they've been run through the drum sander, rip each laminate in half at the drum sander (figure C).

• For the legs, use shorter pieces of 4-quarter stock. As with the center-post stock, cut the strips double-wide at the band saw. By cutting the stock 4-1/2 inches wide, two legs can be glued up at once, and bent both at the same time.

• Pass the strips through the drum sander to remove saw-marks and bring them to a thickness of 1/16-inch (figure D).

• With all of the laminates cut, you can now begin the bending process. Align all the strips for the center-post in a stack, and mark the center-point of the stack (figure E). This will help with positioning the stock in the bending form. It's also a good idea to mark the two outside strips with chalk to indicate the outside faces that won't need to be covered in glue.

• Since there are a total of 24 laminates to glue up, use slow-setting resin glue to allow more working time during the glue-up. Spread the laminates out on a flat assembly table and tape down the ends of the strips to prevent them from slipping.

• Once they are taped down, apply glue to the first side of each laminate (figure F), and spread it evenly across the faces using a glue-roller.
  
• Once the first side of each laminate has a coat of glue, remove the tape. Carefully stack each laminate onto the one adjoining it (figure G), and apply glue to the other face.

• Continue the process until you've stacked all of the laminates for the center-post (figure H).

  Figure G

  Figure H

  
  

  	Figure I
  	Figure J

• Once you have a "wood-and-glue sandwich" of laminates stacked and aligned, you can place it in the bending form. First, secure one side of the bending form to the assembly table using clamps. With the stack of laminates set in the form, carefully begin to bring the two sides of the form together with clamps (figure I).

• Gradually bend the end of the stack of laminates around the curved top of the form (figure J). This step requires a good bit of strength and persistence.
  
• The holes drilled in the form earlier help with positioning of the clamps (figure K).

• As you work your way around the form applying multiple clamps (figure L), tap the edges of the laminate using a dead-blow hammer to ensure that they are seated.

• Glue the legs up in their bending form using the same process as the one outlined above for the center-post. Allow the glued laminates to cure overnight.

  Figure K

  Figure L

  
  

RESOURCES :

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com