DIY Network

Web Extra: Making a Cleat/Cutting Down Laminate Amy demonstrates how to make a cleat and how to cut laminate. From "Freeform Furniture" episode DFFF-201

In this Web extra host Amy Devers creates a cleat for the wall clock and trims laminate.

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Amy demonstrates how to create a cleat.

Making a Cleat

• On the back of the clock there is a built-in cleat. The inside edge of it is cut at 45 degrees and when nested with an opposing cleat on the wall, it will hang flush.

• On layer three of the ultra-light MDF, trace the exterior of the template and the triangle shape jig for the cleat. Drill four pilot holes so that you can insert the saw into the middle of the MDF. Once the pilot holes are in, take two hand clamps and secure the piece to the worktable. Then use the jigsaw to cut the traced shape out of the interior of the piece of MDF.

• Join layer three to layer two temporarily and with double-stick tape and use the power drill to attach the triangular jig to layer two. Use the triangle jig to create the shape of the cleat.

• Flush trim the interior cut-out on the router. In order for the two pieces to nest together, a 45-degree angle has to be cut with a router bit on the inside edge of the piece of MDF that will rest against the wall.

• Take the two layers apart and flip them around so that layer two with the triangle jig is clamped to the other side of layer three (the side that will rest against the wall). Make sure to line up the interior cut-outs perfectly.

• Then use a plunge router and a 45-degree chamfer bit to rout an angle along the length of the cleat. The bearing of the router bit will run along the hypotenuse of the triangle jig.

• Next, clamp the two layers and line them up in their correct orientation. At this point you can join them permanently with glue and brad nails and flush trim the outside of the shape.

Amy also demonstrates how to cut laminate.

Cutting Down Laminate

• Laminate is available in a wide variety of sizes, colors and patterns.

• Use a circular saw when cutting laminate. A jig saw will also work, but the jig saw blade is less likely to produce a straight line. Before cutting laminate, lay masking tape over the cutting line. This will protect the surface and also help prevent chipping. Apply a few more strips of tape on the laminate where the saw base will travel because it can scratch the laminate.

• It is helpful to use a guide to make sure the laminate is cut straight. Use the fence of the circular saw to guide your cut. The T-shaped fence slides into the base of the saw. If you don't have a fence for the saw, or if the cut you are making is too far from the edge of the material, make a guide for your saw using a piece of straight wood or a metal ruler. Clamp the laminate down and be careful to follow the line and exert minimal force on the guide. If you do veer off the line slightly, you can clean it up with a sander or a sanding block.

• The blade for your circular saw should have a thin kerf carbide blade with at least 40 teeth. The "kerf" is the width of the slot that a saw blade leaves when cutting through a material. Thinner saw blades produce a smoother and straighter cut.

• Cut slowly and with steady movement. You might want to make a practice cut first to get the feel of the saw cutting the laminate.

• Laminates, whether plastic or wood, can easily pull and chip when cut. Most saw blades cut on the upstroke which can cause this pulling and chipping. To prevent this, you can use a special reverse-cut saw blade. The teeth on these special blades point downward instead of upward. You can find these types of blades at most hardware and home improvement stores.

• The best way to trim off excess laminate is to use a laminate trimmer. The laminate trimmer works much like a hand-held router. Ride the bearing and the bit just along the edge of the laminate.

• If sanding the edge is necessary after trimming, use 220-grit sandpaper on a sanding block and run it along the cut edge of the laminate at a 45-degree angle, smoothing and slightly rounding it. This should visually eliminate any minor chipping that may have occurred and also eliminate the razor-sharp edge that laminate can get after it is cut.

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