I’ve always been curious about bending or the idea of bent plywood. So for this week’s project, i decided to create a stand for my headphone. We’re calling this project, The t Plywood Headphone Stand. Check it out
BENT PLYWOOD VIDEO BUILD
Create a taper using your tapering jig and your table saw. I went with 2 inches on-top and tapers out to 4 inches over the course of 16 inches.
Mask off 3 inch sections where the bends of the bent plywood will go. I laid mine out at the 5 inch mark from the top, and then another one at the 16 inch mark.
To prevent tear-outs, take this opportunity to add a round over edge if you wish. It will be risky to do it later.
Use a sliding miter saw with a depth to space the cuts about 3/16 apart. Use a scrap piece to butt up against the miter saw fence to allow the blade to cut the whole cross cut of the piece. If you don’t have a sliding miter saw that can have this kind of control, just use your table saw with a sled to create these kinds of cuts. This is the key to achieving the Bent plywood look.
It’s very important to cut all the ply layers except for the last veneer piece.
Remove the tape carefully.
Use 5-Min Epoxy from Home Depot to spread the epoxy into all the slots created on the miter saw. This step is crucial to maintaining the desired bend in the plywood
Create a jig the would mimic the desired bent plywood profile of the desired curve of your stand. My stand has a 75 degree angle.
Use tape to seal off the edges to prevent all the epoxy from pouring out.
Even though the epoxy says it dries in 5 min, I waited until the next day to sand and grind off excess epoxy. I found that using a rotary Dremel tool with an abrasive drum attachment makes it very easy to remove large amounts of epoxy.
Once you remove the large bulk of the epoxy, switch to hand sanding for a thorough finish. I find that using a deep socket wrapped with sand paper does a great job matching the curve of the desired bent Plywood.
Use a band saw to cut out the filler piece that will go between the headphone and the stand. This will make it look slick and smooth.
Glue the piece on top of the stand using wood glue.
Apply finish. I went with the Weathered Oak finish by Minwax to the Bent Plywood Stand.
I used a scrap piece of 2 inch flat bar, roughly 1/8″, heated it with a torch, and started forming an oval for the head profile for the stand. If this part is too uncomfortable for you, use thinner material like 1/16″, that way you won’t need a torch with much effort to bend the steel. This was all I had.
Weld the piece to connect it as one solid circle.
Grind drown the weld bead to make it look flush and continuous.
Squeeze the rough oval in your vice or clamp to form a more even and symmetrical oval.
Hammer out any imperfections on the vice to make it look symmetrical.
Sand and paint it in a satin black paint and primer. I went with Krylon paint and primer.
Epoxy on the black head frame to the stand and use light clamping pressure to let the epoxy dry.
Seal off the entire project with satin water-based clear coat. Be sure to spray a good amount on the black metal ensuring it protects from all the rubbing wear and tear.
OTHER CREATORS AND THERE SUBMISSIONS.
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