As you can see in the post below, The bassinet is really four parts.
A welded steel base
A bent wood form
A bent wire frame with handles, and
A fabric insert.
First, I had to build the form, to bend the 10 layers of veneer (Sheets of thin wood) over.
*Here you can see the form, an elaborate rounded box, hollow, with supporting wood throughout. I covered it with a blanket to try to eliminate imperfections.
Next, after painstakingly gluing all 10 sheets of wood, (8 sheets of inexpensive, sandwiched between two real nice pieces of Walnut), the fun part starts. The wooden form, and the flat sandwich of veneer sheets, are all placed in a large vacuum bag, which is hooked up to a large vacuum pump. (Found at a local wood working shop where you pay by the hour to use their equipment).
*Below is the bag pulled tight, with paper over everything to keep the glue squeeze-out from ruining the bag.
*The bag sits overnight, allowing the glue to dry.
*In the morning, (after lots of prayers and finger crossing....) the bag is removed and the 10 flat sheets have now been bent over the form. First time success is awesome, and very cost effective. Veneer is not cheap.
process is not without a small casualty. I guess that hundreds of pounds of pressure is too much for MDF and some thin sheet wood. The form is busted, (but just the bottom)
*The bent Plywood is trimmed and cut to size, as my helper looks on.
* The welding process begins. I had never welded before, so the whole thing was a great learning experience.
Bending, heating, and cutting metal is much more approachable than you think. Don't let it intimidate you... Oh, and get real good help, like I did. Thanks Greg.
WIth the base finished, the wood is dry fit on top. Pretty good. A mock-up of how to bend the handles is below the base.
*Things are starting to shape up
* Handles bent and fitted, base mounted to wood. Everything is lining up nicely.
Next is the part that makes or breaks the project. The fabric. I actually have as much or more sewing experience as I do wood working. It was also a task, but a fun one. I think that we are there.
*Thanks for following along. This will eventually be put to use somewhere, and has been a great experience to learn some new things. We will continue to do document as best we can, as we create our own home, other peoples spaces, and whatever else comes our way.
All the best,