Popular Woodworking Magazine

From: Subject: Popular Woodworking Magazine Date: Tue, 22 Aug 2006 14:35:50 -0700 MIME-Version: 1.0 Content-Type: multipart/related; type="text/html"; boundary="----=_NextPart_000_0000_01C6C5F8.439D9580" X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2900.2962 This is a multi-part message in MIME format. ------=_NextPart_000_0000_01C6C5F8.439D9580 Content-Type: text/html; charset="Windows-1252" Content-Transfer-Encoding: quoted-printable Content-Location: http://www.popularwoodworking.com/features/printable.asp?id=1068 Popular Woodworking Magazine

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Bending Wood the=20 Wright Way

=95Spread the glue on = the surface of=20 each strip with a 3/8"-32 threaded rod to draw = the=20 adhesive out as evenly as possible. Note that = I=92ve=20 placed the strip on a long scrap to elevate it = above the=20 bench. This allows the extra glue to drip over = the edge.=20

=95Clamp the laminated = strips in the=20 bending form, spacing the clamps every 3" =97 = dead center=20 in the middle of each segment of the press. I = drilled=20 1=BC"-diameter holes in the form to hold the top = face of=20 the clamps and automatically space them.=20

=95 Before you tighten = the clamps,=20 just snug them up to hold the stock against the = form.=20 With a scrap of wood and a hammer, tap the top = edges of=20 the strips to even them up. Then tighten the = clamps=20 until the gaps disappear between the = laminations.=20 =

Cold bending is a whole lot easier with this = flexible=20 clamping fixture.

In my mind, there are three classifications of = woodworking=20 techniques. There are many that I classify as = =93useful,=94 a=20 smaller number that I think of as =93indispensable,=94 = and then a=20 very few that represent a true breakthrough in = woodworking=20 technology. Bending wood is one of the latter.

The ability to alter the grain direction as our = imagination=20 dictates while preserving the strength inherent in a = straight=20 piece of wood allows us to create the elegant beauty = of a=20 continuous-arm Windsor chair and the inspiring sweep = of a=20 vaulted ceiling. We first explored our world in = sailing ships=20 with bent wood hulls, then left it in airplanes with = bent wood=20 wings. Our world would be much less beautiful and much = less=20 exciting without this simple woodworking technique. =

I=92m currently engaged in a woodworking project = designed to=20 create a little excitement, and bending wood is at the = very=20 heart of it. I=92m part of a group of historians and = aviators=20 who are recreating the six experimental airplanes of = the=20 Wright brothers, beginning with their model glider of = 1899 and=20 ending with the 1905 Wright Flyer 3, the first = practical=20 airplane. The frames of these primitive aircraft are a = collection of bent wood parts =97 ribs, wing ends, = braces and=20 skids =97 ingeniously arranged to catch the wind and = lift a man=20 into the air.

True Geniuses Prefer Cold=20 Bending

When most of us hear the words =93bending wood,=94 = we think of=20 steam bending. The wood is heated briefly in = low-pressure=20 steam to soften the lignin (a glue-like protein that = holds the=20 cellulose fibers together). While the wood is still = hot, it=92s=20 clamped into a bending form. The cellulose fibers = telescope to=20 conform to the curve, and the lignin cools to hold = them in=20 place. Or almost. In actual practice, the fibers never = quite=20 conform, and when you remove the wood from the bending = form,=20 there is a great deal of springback =97 the wood loses = some of=20 its curve. If the wood is not attached to the other = parts in=20 the project so as to hold the curve, it may continue = to relax=20 and it will spring back even more. This problem = plagued the=20 Wright brothers while they were doing their glider = experiments=20 =97 they calculated precise curves for the ribs to fly = as=20 efficiently as possible, only to have the ribs relax = and lose=20 a good deal of curvature before they could get their = gliders=20 in the air.

To solve this problem, they eventually abandoned = steam=20 bending for an early form of cold bending. They = arranged the=20 parts of the ribs for their Flyers in a bending form, = then=20 nailed them together with brads. They could not use = glue =97 the=20 adhesives 100 years ago were not weatherproof. A good = rain and=20 the wings would have come apart.

Fortunately, we have a much larger and more = reliable=20 selection of adhesives to choose from than the = Wrights. We=20 decided to make the bent wood ribs of our replica = Wright=20 gliders by laminating the parts with a water-resistant = aliphatic resin (yellow) glue. You could also use = Resorcinol,=20 epoxy or polyurethane glue for an application like = ours. If=20 your project won=92t be exposed to the weather, you = can use=20 almost any good wood glue.

To cold-bend wood, first resaw your stock into thin = strips=20 and plane it so the thickness is even. The thickness = of the=20 strips depends to a large extent on the radius of the = curve.=20 The tighter the radius, the thinner the strips. I use = this=20 chart as a jumping-off point:

=95 2" to 4" radius =97 3/32" thick

=95 4" to 8" radius =97 1/8" thick

=95 8" to 12" radius =97 3/16" thick

=95 12" radius or larger =97 =BC" thick

There are other factors to consider: the species of = wood,=20 the slope of the grain (as it runs between the faces = of the=20 strips), the strength you want, and the amount of = springback=20 you can tolerate. For maximum strength and minimum = springback,=20 we decided to glue up the ribs from 1/8"-thick strips, = although the radius of the curve was nowhere near 8". =

Stack the strips as you will glue them together. If = you use=20 strips that were all resawn from the same board, flip = every=20 other strip end for end to reverse the grain slope. = Spread a=20 thin layer of glue on the face of one strip, lay the = next=20 strip on top of it, spread more glue and repeat. If = you=92re=20 laminating a large number of strips, you may want to = choose an=20 adhesive with an extended working time.

Before the glue sets, clamp the laminated strip in = the=20 bending form. Let the glue set up for its full clamp = time. If=20 you=92re not sure of the clamp time, wait a full day = before you=20 remove the assembly from the bending form. As you = release the=20 clamps, there will be a small amount of springback. If = the=20 curve is critical (as it was for our glider ribs) make = the=20 curves in the bending form slightly tighter to = compensate.=20

Making a Cold Bending = Form

Pretty simple, huh? The only real trick to cold = bending is=20 in making a form that will apply an even clamping = pressure all=20 along the laminated assembly. Traditional bending = forms=20 consist of two parts, the form (the positive shape) = and the=20 press (the negative shape). Both of these parts are = normally=20 cut from the same stock. Begin by drawing the curve = you want=20 on the face of the stock. Cut the curve with a band = saw,=20 separating the stock into two parts. On the negative = part,=20 mark the thickness of the bent wood part. (Tip: Use a = compass=20 like a calipers, set it to the desired thickness. = Follow the=20 curve with the point of the compass, marking the = thickness=20 with the scribe.) Cut away the thickness on the band = saw =97=20 this will create the press.

The trouble with this traditional bending form is = that the=20 press doesn=92t compensate for small variations in the = thickness=20 of the laminated stock or a band saw blade that = wanders a hair=20 off the line. Consequently when you apply the clamps, = the=20 clamping pressure may not be completely even all along = the=20 form. This may result in weak laminations or even gaps = between=20 the laminations when the glue dries.

To ensure that this didn=92t happen to our glider = ribs, I=20 designed a compensating press. After cutting away the=20 thickness of the bent wood part, use the compass to = mark yet=20 another curve on the negative part, this one 1" larger = in=20 radius than the curve you just cut. Saw this curve = then cut=20 the 1"-thick piece into 3"-long segments. Adhere the = segments=20 back to the negative part temporarily with double-face = carpet=20 tape. Glue a strip of canvas to the inside curve of = the=20 segments and cover the canvas with 6-mil plastic.

When you separate the segments from the negative = part and=20 discard the tape, they should be held together by the = canvas=20 like the tambours of a rolltop desk. This is your = press. When=20 you squeeze the laminated stock to the form, arrange = the=20 clamps in the middle of each segment; this will = compensate for=20 any variation in stock thickness or inaccuracies in = the=20 bending form and keep the clamping pressure relatively = even.=20

Note: The plastic on the press will keep any glue = that=20 squeezes out from between the laminations from = sticking to the=20 canvas. To prevent the squeeze-out from sticking to = the form,=20 apply paste wax to the form before each glue-up.

Spreading the Glue

Just as uneven clamping pressure will reduce the = strength=20 of the lamination, so will an uneven application of = glue. You=20 must spread it as evenly as possible, and I=92ve got = just the=20 ticket. This little trick was shown to me by the good = folks at=20 Franklin International (makers of Titebond glue). Get = rid of=20 your glue brushes and spread the glue with the teeth = of a 3/8"=20 x 32 threaded rod. The threads spread the glue to just = the=20 right thickness (about 0.005") for a strong joint with = a=20 minimum of squeeze-out. For this particular project, I = mounted=20 a short length of threaded rod in a wooden handle. = Between=20 glue-ups, I keep the rod submersed in water to prevent = the=20 glue from drying on the threads. PW

Nick Engler is a contributing editor = for=20 Popular Woodworking.=20

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