Recently I was gifted a beautiful sheet of Plyboo (Thank you Arthur and Evan!) and also just moved into a very empty room. To fill this new space, I decided to use the plyboo to make a new desk.
After brainstorming a few different shapes, I decided that California seemed to be quite the right shape for a desk and so I set out to create California.
Materials I used:
3/4 inch, 4 x 8 sheat of Plyboo.
Walnut and Cherry for the legs
Waitco Danish Oil
Vertical Band Saw
Step 1: Cutting The Plyboo
Cutting out California on the Water jet
To cut out California on the water jet, I found an image of the state's border on google and used the make and expand feature(Illustrator) to create vector lines. You can do this in Illustrator by going to:
Object > Image Trace > Make and Expand.
I also used this trace to mock up the desk in Autodesk Inventor. You can also do this in Autodesk Fusion which is free for Enthusiasts!
Next, I set up my Cut path in Omax Layout, exported it to Omax Make, clamped the plyboo to the bed of the waterjet and cut out the desktop.
I was pretty satisfied with the quality of the cut, on the plyboo, from the Waterjet. There were a few very small chipsc on the bottom edge. Also, due to the water and abrasive, small slivers seemed to be coming off of the faces of the plyboo. This could be avoided by hand cutting out the image or using a shop bot.
However, I took care of these small slivers in the sanding step.
Step 2: Sanding
I used an orbital sander to sand the top and bottom of the California. I started at 220 and went up to 1000 grit sand discs. I rounded off the edges with the orbital sander as well. And hand sanded the tight internal geometry.
Finally, I used a tac cloth to remove the sand dust.