| Burl-Veneer Occasional Table -- Tabletop |
From "Wood Works"
episode WWK-206 |
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The Tabletop Once the base structure is assembled and the burl veneer panels for the top have been cut, the next phase in this project is to create the laminate tabletop using the veneer panels and plywood substrate. Once the laminate is done, a frame of rosewood completes the tabletop for the occasional table. Materials: Burled walnut veneer panels
Rosewood stock
Plywood stock for substrate
Table saw
Table router
Vacuum press
Carpenter's pencil
Wood glue
Carpenter's tape
Bricks
Belt clamp
Safety glasses or goggles Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc.
Steps:
- Gluing veneers requires some care and precision since the veneer panels are so thin. For this tabletop, the glue-up is done in three stages. First, lay out the panels in the order in which they were cut (figure A).
- Side-by-side pairs are glued together first. Once the glue has dried, a very fine trim-cut is made along the edge of each glued pair (figure B).
- Then, the two halves are glued together (figure C) to form the complete veneer.
- Use yellow woodworker's glue, and carefully brush it evenly along the edge of the veneer slices, then use tape and clamps to pull the pieces together (figure D).
- Use bricks to keep the veneers perfectly flat on the work surface (figure E) as the glue dries.
- With the veneers trimmed, they are ready to be glued to the substrate. For this table, a piece of 3/4-inch apple plywood was used for the substrate. To maintain equilibrium under the stress of veneering, and to prevent the plywood from warping, the substrate is backed with a piece of straight-grain black walnut veneer. The result is a "sandwich" with the plywood substrate layered between the burl veneer and the black walnut (figure F).
- To cut the veneer to proper size at the table saw, first make sure that the joint lines are centered. Since the veneer is thin, add a plywood caul and some bricks on top of the veneer to help prevent chipping (figure G), then make the cut on the table saw.
- With the pieces cut to exact size, the next step is to glue up the table top. Apply a liberal amount of yellow glue applied evenly to the substrate and the walnut veneer that will be attached to the underside. Join the two pieces together.
- Next apply glue to the veneer top, and stack it all together to make a "wood and glue sandwich." Tape the sides together to prevent the veneer from slipping (figure H).
- Place the tabletop assembly into the bag of the vacuum press (figure I), setting it face down. Before sealing the bag, place a solid piece of MDF on top of the assembly to act as a caul.
- Seal the bag and turn on the vacuum-press pump. When the air gets pulled out of the vacuum press, it results in pressure of more than 1500 pounds per square foot being applied to the assembly (figure J). Allow a few hours for the bond to form.
- With the tabletop assembled, the next stop is to cut the rosewood stock that will frame the finished tabletop. Once the rosewood has been milled and cut to size, a dado is cut into the sides (figure K) to give the appearance of two decorative beads.
- With the fence set 1/8-inch from the router bit, cut the dado in the frame stock with two passes on the router table (figure L).
- Tip: It's a good idea to use fingerboards on the table router when cutting wood as dense as rosewood.
- Once the dado is cut, clean it up using some 220-grit sandpaper.
- With the dado cut to create the "beads," use the miter-jig at the table saw to make a 45-degree miter-cuts on both ends of each piece trim (figure M) -- creating the four corners of the frame.
- With the veneer top dried and trimmed to size, glue on the rosewood trim and clamp the assembly with a belt-clamp (figure N) until the glue dries. Use care to clamp the trim so that it is perfectly flush with the top.
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RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
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
Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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