Forming the Legs
The function of the tools I use and how they work are explained here. Specific tools used are noted in bold.
The table legs are made by laminating five pieces of ⅜” thick bending ply. Bending ply is a type of plywood made specifically for making bent panels. Individually each panel easily flexs in one direction, but when multiple pieces are glued together they form a rigid structure. The bending ply is cut on the sliding table saw, which makes the process easier as the table supports the wobbly ply.
Glue is applied to the plies, and they are placed over a convex form. In our shop we have a large collection of forms, one of which met the shape requirements for this table. Once all the plies are glued, the form and plies are placed in a large plastic vacuum bag. A pump evacuates all the air, resulting in 14.5 pounds of atmospheric pressure per square inch. Each leg then has approximately 13,900 pounds of pressure uniformly clamping the plies together while the glue dries.
