DIY Network

Assembling the Mold for the Ottoman Learn how to attach the braces to the cylinder and the mounting block to assemble mold. From "Freeform Furniture" episode DFFF-206

Host Amy Devers assembles the mold by attaching braces to both pieces of the cylinder. She uses the same technique for the mounting block. She applies clear packing tape to each section of the mold and clamps the mounting table to the lid and screws the two pieces together.

Amy attaches the full circle to the bottom of the mold, clamps the two half-cylinders together and wraps a band clamp around it. Lastly, she removes the lid and screws the bottom piece of the mold to the mounting blocks.

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	Amy continues the Ottoman project by completing the mold for the cork.
	The room—Before
	The room—After

Materials:

pre-fabricated plywood cylinder
3/4" shop grade plywood
handle
screws
packing tape
scrap piece of wood
pen
wax
granulated cork
epoxy
plywood stirring stick
sand paper
sanding block
hollow stainless steel tube

Tools:

table saw
jig saw
combination square
straight edge ruler
hand clamp
router
circle jig
laminate trimmer
round-over bit
braces
mounting blocks
spring clamps
power drill
band clamp
sliding arm clamps
band saw
random orbital sander
150-grit sanding disc
hydraulic roll bender
computer numerical controlled (CNC) mandrel draw bender
TIG welder
awl
drill bit

	Figure A
	Figure B
	Figure C

Assembling the Mold for the Ottoman

1. A good way to hold the mold together in order to get the cork in and a good way to disassemble it is to make braces to attach to the end of the semi-circles. That will give you a nice hold for the clamp. Use two spring clamps to secure the brace to the wood and a hand clamp to secure it all to the table (figure A).

2. With a power drill, screw on the braces to both pieces of the cylinder.

3. Use the same technique for the mounting block that you just did for the braces. Screw them all into place so they are flush with the bottom of the mold (figure B).

4. Adhere strips of clear packing tape across each section of the mold. Take a scrap piece of wood to smooth out any discernible creases in the tape. Don't put any tape on the wooden mounting plate because that will be glued up inside the cork.

5. Draw the guide marks on the lid for the mounting plate. The mounting plate will actually become the bottom of the ottoman and you will attach legs to it later.

6. Clamp the mounting plate to the lid for a tight fit and screw the two pieces together.

7. Attach the full circle to the bottom of the mold. This will create the indentation in the top of the ottoman. You will flip it over later so that it forms the top of the ottoman.

8. Using the lid to ensure correct spacing, clamp the two half cylinders together and wrap a band clamp (figure C) about it to hold them firmly together.

9. Remove the lid and then screw the bottom piece of the mold to the mounting blocks.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.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

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

MacBeath Hardwood
Website: www.macbeath.com

IMS Metal
Industrial Metal Supply Company
Website: www.imsmetals.com

Metal Powder Coating
Steve's Plating Corporation
Website: www.stevesplating.com

GUESTS :

Steve Knez
Steve's Plating Corporation
3111 N. San Fernando Rd.
Burbank, CA
Phone: 818-842-2184
Website: www.stevesplating.com