This is my first attempt at creating a bent lamination which requires a form to clamp the bent pieces while the glue sets. I’m working on a Bow Front Table, where the apron is a bent lamination, made up of six 1/8″ x 4.25″ pieces of walnut.
The form ends up being six pieces of 3/4″ MDF stacked to end up a total of 4.5″ high. The process is to take time creating the first piece and from there: rough cut the next piece, attach to the first, flush trim it with a router, rinse and repeat.
I first spent a little time to square each piece of MDF using the tablesaw which wasn’t strictly necessary but I like starting with square pieces. I then concentrated my efforts on making the first template. I traced the curve onto it and roughed it out with the jigsaw. I also roughed out the same curve on the back so that clamps are 90 at both ends. I clamped and flushed the curve with the router. One down.
The rest went really fast. I traced the first template piece all around onto the next MDF piece. Using the jigsaw to rough it out, I actually ganged two MDF pieces together and did them at the same time. I then countersunk and screwed the second piece to the first template. I didn’t end up using any glue so I can take it apart later if I want. Then around all the sides with a flush trim bit and we’ve doubled our height. Pieces 3-6 went in the same manner.
All in all it was a fast process to make the bending form. The first piece took a little time to get right, but the rest went very quickly. My biggest problem was cleaning up all the MDF dust at the end. I really do want the Festool Router with built-in dust collection!
Next up is to use this puppy!