DIY Network

Freeform Furniture: Prefabricated Plywood Cylinders From "Freeform Furniture" episode DFFF-103

In this opening segment host Amy Devers introduces plywood cylinders. She rough cuts them down to the proper dimensions with a jigsaw and then uses a table saw to cut them down to the exact size. She adds braces to the inside of the cylinder to accommodate screws for the top and bottom piece. She uses a band saw to cut the top and bottom pieces, then glues and attaches the top and bottom pieces. A router is used to trim off the excess pieces.

advertisement

Host Amy Devers shows you a unique way to create outdoor furniture using prefabricated cylinders.

Materials:

Prefabricated plywood cylinders
1" x 1" glass tiles
Plywood
Solid surface material
Prefabricated furniture feet
Combination square
Pencil
Screws
Wood glue
Clamps
Glue
Small drill bit
Safety glasses
Thin-set white mortar
Trowel
Wooden board
Spray bottle
Bucket
Dollop
Tape measure
Double stick carpet tape
Dust mask or respirator
Chamfer bit
Sanding block
320-grit sandpaper
T-Nuts
Polyurethane construction adhesive
Caulking gun
Framing square
Bright white sanded grout
Hard rubber grout float
Big sponge
Water
Cloth
Dental tools
Grout sealer

Tools:

Jigsaw
Table saw
Drill
Band saw
Router
Rubber mallet
Circle cutting router jig
Flush cutting bit
Drill press
Hammer
Forstner bit

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

Plywood Cylinders

Note: Prefabricated plywood cylinders can be found at most specialty lumber suppliers. They come in a big range of lengths and diameters and range in price from $50 to $200 depending on the size.

1. To mark the cylinders for the cut, use a combination square and pencil. With the pencil running along the edge of the ruler, slide the head of the square along the bottom of the cylinder and mark around the entire circumference (figure A).

2. Using a jigsaw, cut the cylinder a little proud of the line.

   Note: The term proud means to cut a little oversized.

3. Once it is rough cut to a manageable size, cut it down to its exact height on the table saw. Slide the cylinder onto the blade and then roll it clockwise -- applying even pressure against the fence and the table.

4. Once the tables are cut to length, cap them off with a plywood top and bottom. If the wall of the tube is thin and there is not much for the screw to bite into, you can add plywood strips inside to give you something to fasten the top and bottom to (figure B). You screw them in from the outside (the screws will be covered by the glass tile).

5. Mark the positions of the four braces on the edge of the cylinder. Flip the cylinder over and then draw lines with a combination square to reference where you will be drilling holes.

6. Run a bead of glue, and then hold the brace in place using a clamp.

7. Drill a pilot hole and drive the screws in place (figure C). Repeat this process for the remaining three braces.

8. Cut the plywood for the top and bottom a little proud of the line. Trace the cylinder on top and then cut it using a band saw (figure D).

   Note: If you don't have a band saw, you can make the cuts with a jigsaw.

9. To attach the top cap, apply a bead of glue on the top edge of the cylinder and then center the cap on the center (figure E), leaving a small overhang all the way around.

10. Flip the cylinder over and repeat this same process for the bottom.

11. Use the lines on the outside of the cylinder to locate the interior braces. Drill pilot holes through the plywood cap and drive screws through the cap into braces inside (figure F).

12. With the caps screwed in place, clamp the cylinder to the table and begin routing the top of the cylinder.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.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

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.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

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Glass Tiles
Website: www.crossvilleinc.com

Solid Surface Materials
Pinnacle Distribution Concepts
Website: www.pdc4surfaces.com

Woodcraft
Website: www.woodcraft.com