Round Wood Table, Getting The Top Buttoned Up. Part 2

Before filling out with the honeycomb material, the round inner and outer edges needed to be trued.  We made a curved sanding block by taking a piece of 8/4 poplar and tracing a curve and then cutting close on the bandsaw.

Tracing the curve

We then used 80 grit 3M stickit paper  attached to the table edge to sand and true the block.  The next layer, 1/4″ MDF and the top veneers will be flush cut to this edge so we want it nice and smooth.  No mill marks or chips outs that the router bearing could find.

80 grit 3M Stickit paper

Tuning up the sanding block

Once the edge was sanded, it was time to add the Resin Impregnated Honeycomb.  It was very easy to rip the material on the table saw and use a straight edge and matt knife to cut the angle cuts. The sheets come in 2 ft x 4 ft pieces and we were able to use the angle cut offs to be more efficient in the use of material.

Filling out with Resin Impregnated Honeycomb

The last picture shows all the honeycomb in place.  We then took all the pieces out and vacuumed before gluing.  We used Unibond 800 as it has a long open time and rolls on easily. The compartment and the framing was coated and then the backside of the MDF was coated. We did 1/2 of each side at a time so as not to have any kind of glue up panic. We used a narrow crown staple  3″ on center.

After the glue dried overnight, we flush cut the excess MDF and flipped the table over to do the other side. We could tell the table was much stiffer after the first layer and very stiff  when the 2nd side was done. The next post will be on cutting the veneers to getting them edge glued in section.


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Looking good! Can’t wait to see the end result.

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