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Building a Small Entertainment Center

Making Curved Cabinet Doors

Having built the two forms, it was time to fasten the two layers of 3/8" bending plywood. Using blue painters tape, I marked the starting point for the bending plywood, ensuring the edge is in the proper place, as well as make sure the bending plywood isn't glued beyond the desired point from the glue squeeze out. The layers are stapled on both sides, moving equally along the form preventing twisting or distorting of the door blank.

Gluing the first layer of bendy board 1  Gluing the first layer of bendy board 3  Gluing the first layer of bendy board 6

As shown in the third picture, using squeeze clamps to clamp the bending plywood to the form structure, keeping the edges of the door straight. Without this step, the front and rear edges could end up warped. That would be very difficult to fix, and be very obvious.

 
 
 
 

The second layer of bending plywood is fastened in the same way, with the addition of urea resin glue between the layers. This is a rigid glue, and will keep the shape of the curve, when the form is removed. One the glue has cured, I use a straight edge clamp to use to guide a small circular saw, known as a trim saw. This saw, made by Porter Cable is a terrific saw for many uses, and the fact it is a worm drive saw, makes it surprisingly powerful. I've had the same one for over twenty years, without any trouble or maintainance, other than changing the gear oil. The saw is set to the desired angle, and the door blank ripped.

Both doors glued up  Trimming the door edges  Cutting the mitered edge on the door 1

Please note I normally don't dress quite so formally for this type of work, but I wanted to show off my new hair style, and buffed body. LOL Care in this first step in ripping the edge, will make the following steps easier to keep parallel and square.

After the initial rip, cutting the parallel edge was done on the table saw, also at the desired angle. The next step was to carefully cut off the top of the form using a band saw. With a nice straight I can use the fence on the table saw to lightly trim the bottom edge on the table saw. Notice part of the bottom form on the door has been left in place. This will serve as a storage space for audio and video cables.

Using a shelf to mark the desired overhang.  Carefully cutting off the top form on the bandsaw  Trimming the bottom of the form on the table saw

With the help of european hinges, I was able to intall the first door with little trouble. I did clean up all the edges with a block plane, but that was quite minimal. The installed door looks and funtions well. I installed a small vertical piece at the base of the door on the inside, to serve as a storage space for video cables and remotes.

Curved Door Installed  Curved door opened

Well, one more curved door to complete, then two flat doors, and I'll be ready to veneer them. After that, it's a matter of finishing the top, and getting my wife to pay me!

 

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