Bending plywood

[Joe V]

I'm in the process of building a bathroom vanity that has a curved front. The caracass is complete and the upper and lower approns I kerfed the back of the plywood (maple) and it bent beautifully. Now I have to give the same curve to the two front doors, approx 15"x23". What I have done on a test piece is to kerf the back of what would be the door and then glued a piece of 1/8 bendable plywood to the back to cover the kerfs, clamped to a template while the glue dried.

Is this an acceptable way to achieve what I need? Will the doors maintain there shape? Are there any other suggestions for bending plywood or for doing these doors?
Thanks for any advise or insights

Joe

[Sawduster]

I think to insure that you don't get spring back either when you remove the clamps, or further down the road, I think I would cut at least two, and probably three, pieces from solid stock with the required curve, less the radius difference for the thickness of the bent ply, and glue the kerfed ply to those, one top, bottom, and center. Then glue the 1/8" onto the flat back so as to make a sort of hollow core door.

See picture for what I'm talking about.

[Joe V]

Jerry:

Thanks for the quick response and suggestions -- sounds like a good idea to me. Will try it this comming weekend and let you know.
Regards
Joe

[Joe V]

Jerry:

Here is the execution of your idea -- looks like its going to work great. I just have to glue the skin to the back and it should be ready to go. Thanks for you help
Joe

P.S. Having trouble uploading the JPEG file -- I think its too big. More that happy to e-mail it you if interested.

[Sawduster]

Hey Joe,
There's a size limit on files uploaded to the site. Anything over about 75 DPI is wasted on a normal PC screen, so that's okay. I normally go into my photo software and reduce them to 72-75 DPI, then save with a new name so I have the original high res and a lower one for posting.

I've got a size limit on my e-mail folder (one of those free hotmail accounts) but it it isn't too large, you can e-mail it to me.

jerrypalmer82@hotmail.com

Put something about woodworking in the subject line cause my junkmail filter filters everything from anyone not in my address book into a junkmail file and I just scan it and delete everything from anyone I don't know that doesn't have specific buzz words in the subject line. Once I receive an e-mail from you, I will add you to my address book so the mail won't be filtered.

[Joe V]

Jerry:
I reduced the size of the photos and trying again
Joe

[Sawduster]

Joe, that does look pretty darn good. Be proud, fella.

[rburkett1]

Hey Joe,

Your doors look really cool. May I ask what thickness of plywood you used and how deep you cut the kerfs? I have a similar project in the thinking stage and could use the info...

Thanks,
Ron

http://basecamp-1.com/ronsworld/woodwork/projects.htm

The more I learn, the more I learn that there's more to learn!

[Joe V]

Ron:

I used 3/4" plywood with a maple veneer. I didn't measure the depth but I set the depth so that the veneer and one layer of plywood were uncut. I left 3/4" on each of the vertical sides and the spacing was set using a piece of 1/4" hardboard -- i.e. I would cut the first kerf, then insert the 1/4" hardboard between the fence the and the door and cut the next one -- when that was cut I would wait till the blade stopped, slide the door onto the blade, remove the 1/4" hardboard,move the fence against the door, remove the door, and insert the 1/4" board back and cut the next one -- a bit tedious by it worked. Its a little easier if working with something not as big were you can use the mitre gauge with a nail set in for spacing. I used 1/8" bendable plywood on the inside to cover the kerfs.

Hope this helps.

[rburkett1]

Thanks Joe, I appreciate your taking the time to respond and explain your technique. That information will be helpful.

Ron

http://basecamp-1.com/ronsworld/woodwork/projects.htm

The more I learn, the more I learn that there's more to learn!