DIY Network

Creating the Template and the Hardboard Learn how to create the wall clock template and hardboard. From "Freeform Furniture" episode DFFF-201

Host Amy Devers traces out the design for the clock and carves out the template. She then creates the shape for the clock on tempered hardboard using a flexible curve, a compass and the minute hand of the clock. After gluing the paper to the hardboard, she cuts the hardboard with a band saw, drills pilot holes in it, secures it with clamps and uses a jig saw to cut a rectangle in the middle.

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	Amy creates the template and hardboard for the wall clock.
	The finished clock

Materials:

laminate
dye-cut tin hands
upholstery tacks
medium-density fiberboard
tempered hardboard
flexible curve
compass
minute hand of clock
pencil
paper
straight edge ruler
square ruler
spray adhesive
respirator
safety goggles
yellow wood glue
double stick adhesive tape
water-based contact cement
paint-trim roller
clear packing tape
brown craft paper
paint
pliers
screw
nut
hex nut
awl
blue tape
forstner bit
counter sink bit
eraser
high torque quartz movement
AA battery

Tools:

drill
jigsaw
band saw
spindle sander
laminate trimmer
hand clamps
wood file
pneumatic nailer
flush trimming bit
"J" roller
mallet

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

Creating the Template and Hardboard

Note: The design used for this clock has a shape that evokes a sort of hyper-stylized abstract piece of burl wood. Burl wood is rounded knots that come from tree trunks (figure A). In the 60's tables and other things made out of burl wood became very popular. This project was made out of laminate. Laminate is paper that is combined with chemical resins that turn it into a dense hard plastic. It comes in many different colors and patterns. Two patterns were chosen for this wall clock. The face is a laminate that has a black and white wood grain pattern and the edge has a laminate that has a photo realistic imagery of bark (figure B). The hands were ordered from a company and they are die-cut tin. Die-cutting is a manufacturing process in which a heavy-duty cookie cutter like tool is used with extreme force to press out that shape. For the numbers, upholstery tacks were used.

1. Measure out and create a template for the shape of the clock. Do this on a piece of tempered hardboard--a wood product made from thin sheets of compressed sawdust and wood chips.

   Note: Tempered hardboard is perfect to use for templates because it is inexpensive at $15 to $18 per 4 x 8 sheet, and it is easy to work with.
   
   

2. Cut down a piece to 2' x 2' (that is the target size of the perimeter of the clock).

3. Mark onto the paper how far the minute hand will extend from the center of the clock.

4. With the compass, trace the circumference of the circle that will form the face of the clock.

5. After you draw out the circle, use a flexible curve to create the curves for the edges (figure C).

   Note: The flexible curve is made of lead that is sandwiched between steel ribbons and covered in flexible plastic. It is a great tool because it allows you to adjust the contours into the shape you want. You can purchase one at most good art supply stores for $8-$10.

6. When the exterior shape is drawn, draw a rectangle in the middle of the paper. Use a straight edge ruler to draw the center line. Use the square ruler to find the center point of the shape (figure D) and finish up the rectangle.

   Note: Later on you will cut the rectangle out of the back of the clock to make room for the clock mechanism and the cleat.

7. Once the entire template has been drawn out, it is time to glue it to the hardboard with spray adhesive. Spray an even coat across the hardboard.

   Safety Tip: Always put on a respirator when you use a chemical spray and work in a well-ventilated area.

8. Line the hardboard up to the paper template and press it firmly into place.

9. Cut the shape out on the band saw. The blade on the band saw is actually one continuous piece of metal that spins around at high speed on these wheels. That allows you to make the freehand curves for the template. Lower the blade guard to just above the wood and make the cuts. As you feed the hardboard in and around the band saw to make the curves, take it just over the line (figure E). The edges will be a tad rough when finished and can be smoothed out later.

   Safety Tip: Wear safety goggles to protect your eyes from flying wood particles.

   Note: The form of the clock itself has two different types of curves--concave and convex. Concave curves are cut inward like a cave and convex curves round outward.

10. In order to cut out the rectangle in the middle, use a jigsaw because the jigsaw is the perfect tool for doing interior cutouts. You can't just plunge the blade directly into the tempered hardboard, so pilot four holes first. Drill four holes into each corner of the square. Once the pilot holes are in, secure the piece into place with two standard hand clamps. Insert the jigsaw into the first pilot hole and apply forceful, yet even pressure on the jigsaw as you work across each line of the rectangle (figure F).

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.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

WMH Tool Group
Website: www.whmtoolgroup.com

Lie-Nielsen Tookworks, Inc.
Website: www.lie-nielson.com

Wilsonart Laminate
Website: www.wilsonart.com

MacBeath Hardwood
Website: www.macbeath.com