Instructables

Cork Board Project phase 4

Picture of Cork Board Project phase 4
I made this at the TechShop (www.techshop.ws) in Menlo Park.

This is a continuation of the series of Instructables for the Cork Board Project.

These boards need two surrounds of corks lying horizontally. For convenience in mixing and matching the corks, I created a jig for gluing a line of corks together, end to end. When the glue has set, the line of corks can be treated as a unit. You may find this is convenient both in design and assembly.

The corks are dabbed with glue on the ends and put in the jig, one by one. Then the bolts at the end are gently tightened to hold them in place as the glue sets. Later the units are removed for use in the cork boards. This system allows for treating the cork boards as a production line if you want to do it that way.

This was designed for my project, but will be useful for anyone making similar corkboards.
 
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Step 1: Tools and Materials

Tools used:
Table saw.
Miter saw.
Screw driver.
Drill press.
Clamps.

Materials:
3/16" plywood from the scrap bin.
1/2" plywood from the scrap bin.
3/4" wood plank from the scrap bin.
1" Screws.
1/4" bolts 3" long.
Wood glue.


Step 2: Design.

Picture of Design.
The design is a jig with several channels (eight in this case) side by side, to hold the corks while they are glued together and the glue sets.

The width of the channels should be just enough to hold your corks (meaning you need to measure them first) plus the thickness of a layer of polythene sheet. Obviously, the polythene is to separate the corks and the glue from the wood of the jig. This width is the most important dimension in this project.

Two other choices are the number of channels (I chose 8) and their length. There are 8 channels because there are two surround layers and four sides. The length should just be enough to hold the longest line of corks plus the compressing bolt. I chose 16".