Kerf Bending Plywood – DIY Ottoman Table Build


The problem: Ottomans take up space, no room for coffee table.
Ripping 16″ section off birch plywood panel.
Marking the center to find where the corners will be.
Seven kerfs spaced 1/4″ apart.
Raising blade to leave just 1/8″ of material.
Scariest part! Running the plywood to cut the kerf.
Phew!
Cutting the rest of the kerfs.
Test bend.
Set depth of circular saw to almost bite through.
Plunge cut.
These create space for hidden splines.
Test bend.
Scrap hardwood ripped to fit in the circular saw kerf.
Cutting out splines.
Ready for the glue up!
Apply a lot of glue!
Clamp and check for square.
Insert splines and let dry for a few days.
Old desk leg, apply adhesive and sandpaper.
Perfect for cleaning up the inside curves.
Fill any left over voids.
Sand smooth.
Not bad!
Placing together leaves a void. Let’s fix it!
Marking so it will be flush with the flat surfaces.
Cut out on the bandsaw.
Round edges on disc sander.
Creating the center strip.
Setting blade to cut 15°
Slicing one side.
Flip and slice other side.
I went as far as needed, killed the table saw and took out the piece rather than run it entirely through unsafely.
That’ll do.
Marking out the profile for a lap joint.
Cutting out on the bandsaw.
Gluing in place.
Apply polyurethane.
Line inside with a slippery material.
Trim flush with razor blade.
It fits!
This one fits too!
Move two together to add the flush insert.
Glamor shots.

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