I'm making a book case for my daughter and she wants a curved top. I have made a form over which to do the bending but I am having a problem with the
1/4" plywood splitting. I can not use 3/4" plywood and make cuts in one side as both the top and bottom with be visible so I decided to laminate 3 pieces of 1/4" plywood. I plan to use polyurethane glue to do the lamination but I need to conquer this splitting problem. I would appreciate any help you can offer.
Watch the grain direction of the top sheet. You want to orient the grain so it is perpendicular to the direction of the bend.
Also, try bending plywood for at least the middle of the three layers. You may not like it for exposed surfaces. Doug suggested using three layers of this, and veneer for the exposed surfaces, which IMO is the way to go if you have a way to apply the veneer.
Dick, I'm with Lew about the Epoxy. If not that, I'd go with Titebond II or III before the poly.
Steam, soak, or 'local hot towel' if you want to use the stuff you already have.
Cut your pieces 'over length' by a good bit. Re-make the form with a tighter curve then the finished lamination {to allow for 'springback'}. Soak the pieces - in the bathtub if necessary. {If still not long enough . . . lay out a piece of plastic, put hot-water soaked bath towels on it, lay the strips of ply on the towels and roll them up, wrapping the plastic around all.}
Take out the ply strips, and clamp to form, piece by piece. Either 'square' at one end and let the other 'stairstep', or let both ends 'stairstep'. DO NOT glue and use LOTS of clamps. Let completely dry . . . I'd go at least a week.
When dry, unclamp, apply glue, and re-clamp. After another week, unclamp, sand sides, and trim to square off ends. Do whatever edge treatment you want and trim to final size just before assembly.
The problem I think will be that the book case has to be stained to match other furniture in the room that is birch. I'm worried that if I buy bending plywood, it will not match. Thoughts?
I'd follow Ron's advice. I had a question or two on my first bent lamination and his thoughts were right on. As for the wetting I suggested, I know what a piece of ply left out accidentally in the rain looks like!
The wood was splitting in a line parallel to the grain. I am bending with the grain and it was splitting along the grain and not at the lamination. I have gotten lots of great advice from this group (as usual!) and I am going to get some bending birch (it is made using a radial cut so it has a natural bend to it) from Boulter Plywood here in Boston and I am going to use epoxy to do the lamination rather than the polyurethane glue I had planned on using.
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