Kerfing Panels to Bend

[nat_wheatley]

I need to make up a series of laminate faced panels to mount to the face of a curved desk. In the past I've used Kerfcore, but would like to try to make them up myself this time. The curve of the desk isn't extreme, but the panels will need to be able to bend a fair amount, not sure of the radius of the desk offhand.

I'm open to suggestions, but my thought is to use 3/4" MDF as the substrate, then do a series of 1/4" kerfs on the backside, 1/2" deep, 1/2" on center.

Thanks.

[jseiler]

What about wiggleboard (aka wackywood). Its plywood with all the plys running the same direction.

http://www.packardforestproducts.com/bending_plywood.html

John

[cabnet636]

kerfing (even kerfcore) has too much potential for segmenting, i always use benda ply, wigglewood, 3/8ths bending luan

jim

[dlcw]

Nat,

I concur with John and Jim about the bendy plywood. I've used the stuff in several freeform pieces of furniture and cabinetry and they turned out great. This Church pulpit, I did about 3 years ago by building forms and then applying bendy ply over the forms, filling, sanding and then applying veneer. All using a simple vacuum press.


7787
The leg frame


7788
With bendy plywood


7789
Applying veneer

It sounds like you might be able to use the same technique for your project.

Don
www.diamondlakewoodworks.com (http://www.diamondlakewoodworks.com)

[nat_wheatley]

Thanks for the posts. What I neglected to mantion is that the panels will be applied/shaped to the desk in the field. I think I do need to stick with the kerfcore concept, with the wacky wood, once I laminate the face, would I then lose the flexibility?

[joe]

Wow Nat.

Can't wait to see the finished product. Your off to another excellent finish.

Joe
www.normansignco.com (http://www.normansignco.com)

[dlcw]

Nat,

If you laminate with glue like plastic resin glue, then you will loose the flexibility. A yellow glue might be a little more flexible.

If practical, another option is to make a template of the desk, bring it back to the shop, glue it up and then install. This would make the panels fit perfectly. Just some thoughts.

Don

[r_jones]

Anyone ever use any Kerfkore?
http://www.kerfkore.com/

[nat_wheatley]

Ron,

I used Kerfcore on the last curved desk we did. It works very well, but is not inexpensive. We paid $150/sht.

[coach]

My concern when doing the process you speak about was flat spots on the radius.
I have a job in the wings that will need radius fronts. I will be interested in your choice and results.
What about using 1/4" birch ply and doubling up the material?
Seems quite flexible but depends on the area.

[tgm]

The best product we have found for curved work, after using all the above mentioned items, has been "ECONOCORE" made by the makers of Kerfcore.
It's a hardboard faced MDF product that performs superior to all others. Cost is approx. $50 for a 3/8" thick sheet. Perfectly smooth face, no segmented or faceted faces and works well.We have been using it for the last 15yrs and thru all of the 'wacky wood' away when we switched. I can't imagine trying to use that stuff again.

Tom in PA

[cabnet636]

ive used the kerfcore and went back to bendy ply. we have done quite a bit of radius work over the years and it is alway's about the form the skin is just that.

jim
7790

[wberminio]

Check this out.I've made my own with the Shopbot in the past. http://www.outwatercatalogs.com/lg_display.cfm/catalog/2009_master/page/498

Erminio

[nat_wheatley]

Looks ideal, but does say 'shape first - then laminate'

I am going to try doing a few sample different pieces on my machine. Erminio was good enough to call to describe the process he used, which seems very good.