Instructables
Picture of Plyboo California Desk
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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

Tools used:

Adobe Illustrator
Waterjet
Orbital Sander
Drill press
Screwdriver
Disc Sander
Hand drill
Vertical Band Saw

 
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Step 1: Cutting The Plyboo

Picture of Cutting The Plyboo
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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.

Results:

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

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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.
hfnet28 days ago
gronan17 months ago
Darn nice work. Seeing as I have no access to A water jet cutter my desk will be cut out with A More conventional tool...A saw! So I better start out with South Dakota!!
DIY Dave9 months ago
Hmm...an Indiana desk wouldn't be too difficult
thesealy9 months ago
How much would it cost for you to make another California top, un sanded and finished and ship it? I am interested in that! But don't have a water jet cutter
gravityisweak9 months ago
One down, 49 more to go! That'd be one hell of an office set. The Rhode Island desk goes to the new guy.
sabrososki9 months ago
love need to make me a p.r. one
SlavicFMJ9 months ago

Wow, that is such a great idea! State size table!!! Good job!

Jeffo239 months ago
Holy Mackerel that's cool!
King of Clubs9 months ago

Awesome! You should enter this in the woodworking contest.

kevenr179 months ago

Very nice!! Good Job!!