Second go-round with the cone corner desk

[Crazyraceguy]

Ultimately, there will be 8 of these things. This second version has one major change that will make it far easier to build. Outwardly it will look exactly the same, this is just an assembly modification. My idea for the change was initially just about making that transition to the bevel easier to trim around. As it turns out there are 2 other benefits, from the same change. It will make assembling and sanding the solid surface lower countertop, during the installation process, far easier too. The 3rd benefit is that the parts nest together much better for the CNC too. So, even though there are added pieces, it took less plywood.
Just the top/bottom plates and the vertical "studs" require 6 1/2 sheets of 3/4" ply and the sub-tops needed another 6 sheets.
The main CNC guy was off yesterday, so I ran the parts myself, (on the secondary machine) while the other CNC guy was running cabinet parts on the "big" machine. It took about 2 1/2 hours to cut out all of these parts.
I got shifted onto something else for the rest of the day and part of this morning, but I got the frame completely assembled by the end of the day. Now, beveled section is separate from the vertical wall section. This will make laminating and trimming a lot easier, probably easier to ship also.
It's kind of a time study, to see how much faster the second unit can be built, but the results can never be perfect. I did all of the kerfing and bevel routing of the cone parts for the first 4 sets of these while building the first one, plus the jig building time went there too. I didn't have any CNC time on the first one though, so that's different too. I expect 30-40%?

 

[afish]

I wana see the top part as a large cove

 

[Crazyraceguy]

I wana see the top part as a large cove

I'm sure that it would look great, but it would be quite a challenge. It would not be possible with the plastic laminate. It will curve/bend both directions, but not at the same time.

I did get it taken apart, skinned the lower section, and back together.

 

[Crazyraceguy]

Update. I got the upper (tapered) section assembled, skinned and laminated yesterday. Today was the laminate on the lower wall and rejoin the top to the lower. All it needs is the laminate on the inside. Should be done tomorrow, assuming no interruptions, maybe not early enough to get it back apart for shipping? but effectively done. 

 

[jcameron42]

Great work

Sent from my iPad using Tapatalk Pro

 

[afish]

yep great work and nice to see the designer didnt ruin the entire job by picking some awful laminate this time. 

 

[Crazyraceguy]

yep great work and nice to see the designer didnt ruin the entire job by picking some awful laminate this time.

Thank you, that means a lot.
As I kind of expected, I never got to touch it Thursday at all. I did get in a few hours on Friday, but not done yet.

The covering on the outside is very odd to work with. It is not the typical HPL that most jobs get. It is a fairly thick (.075") PVC. It cuts nicely with the TS55 and routes decent with a flush-trim bit, but on a table saw it "chunks" out terribly, unless you use a ZCI. Soft/flexible and brittle at the same time?
The worst part is that it can create enough static charge to set off the Saw Stop!
I did that entire first desk with no problems at all, but after a single cross-cut of 48" and about halfway through a full length cut, bang! and the blade was down.

 

[afish]

Thats interesting any more info on the pvc?  maker/cost?  Its probably super expensive... Also what happens on the top? Im assuming some type of solid surface with an overhang. Otherwise that top edge looks like it could be super sharp.

 

[Crazyraceguy]

Thats interesting any more info on the pvc?  maker/cost?  Its probably super expensive... Also what happens on the top? Im assuming some type of solid surface with an overhang. Otherwise that top edge looks like it could be super sharp.

I don't remember the name of the PVC right off, but can look at it Monday.
The tops are indeed solid surface with a bullnose edge to soften the whole look. Eventually I will get some pics of these installed. Buy the time this project is finished, there will be 8 of these, mostly the same, with slight variations in the length of the straight sections. This one is a mirror image of the first one. They sit opposite of each other in each wing of the building.

 

[Crazyraceguy]

Finally got to it enough to test fit the sub-tops and break it down for shipping....just in time to start on the next one tomorrow morning.
afish, the PVC is made by a company called InPro. It is intended to be wall protection for drywall walls, not just scuffs/scrapes but actual impact that would puncture drywall.

 

[afish]

Thanks for the info It sounds similar to the stuff (i cant remember the name) that we used to put on the lower 3rd of hospital walls.  It was a thin solid color core pvc sheet with a fine texture on it similar to melamine.  We had a name for it but that was many moons ago.  You just sticking it with contact?

 

[Crazyraceguy]

Yes, the same contact that we use for all laminate work. The recommended adhesive is actually a water-based product that is troweled on, wall side only, and allowed to dry. It works basically like contact cement, but it takes way too long to dry.

I started on the 3rd one today. I got going on the CNC first thing and promptly got interrupted with something else. I did get back to it long enough to get the frame assembled. 

 

[afish]

Yea thats how we used to stick it to the wall with some type of water based glue and a very fine notched trowel.  Sounds like the same stuff.  Never thought about laminating cabinets with it though.  I would make for a very durable finish. 

 

[Crazyraceguy]

A couple more pics of the 3rd one, with the oddly satisfying clamps in a line.