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We decided that white melamine particle core board would work for the base —
and we have so much of it.
Here, Elena has cut the board to size and is using my favorite
Plexiglas template to round the corners.
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She uses a top bearing flush cutting bit
to give her the perfect finished rounded corner.
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She has installed a CMT slot cutter (5/64") in the
Festool OF1400 router and sets the cutting height so that the slot will be
at the mid-point of the edge.
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She uses a rubber
mallet to coax the plastic edging around the base. For the corners, she has
cut "vees" into the spline so that the bumper can make the bend. She
also uses a spot of CA gel at the starting point to lock it in position.
I get the edging from
Woodworker's Hardware. It comes in a variety of widths and colors.
I try to keep the 13/16" width in white and black in stock. It is
inexpensive and comes in quite handy for projects like this. And it does
keep the white melamine from chipping.
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To bend around a corner, it is necessary
to cut "Vees" into the tongue and remove portions. This will depend on how
sharp the corner is.
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We use a small dab of thick CA gel from
our handy FastCap CA kit. Follow this with a spray of accelerator and the
bumper will hold in place after about 11 seconds holding time.
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We use the nylon filament strapping tape
as edge clamps to hold the black edging in place while the glue sets. Apply
a few inches on top surface and then pull over the edging and fasten a few
inches on the underside. Using the CA glue might make this step unnecessary
but better safe than sorry.
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