Kerf Bending Plywood - DIY Ottoman Table Build

My in-laws got a new couch and it came with a bunch of ottomans (ottomen?) which meant no room for a coffee table. Not ideal, especially for a family who plays a lot of board games. I decided to make a removable cover that would convert them into usable table space. An additional insert makes the two into another a contiguous flat surface.
The results are fantastic. The hidden splines give it plenty of strength along with the wood glue. They are removable in case you want to use the ottoman and can even stack 90° to one another if you want a stand-alone table.
That said, I'd recommend going the extra mile and doing bent lamination with thin plywood instead. Cutting so many kerfs in such a long piece of plywood was really high pressure; the blade set too high and it cuts through, the blade set too low and there's little chance you're going to run it through EXACTLY the same path to hog out just a tad bit more material. One small slip and that whole piece is ruined. Bent lamination isn't easy, and arguably you need more to accomplish it, but it's a little bit more forgiving and it'll be much more strong than this.
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► GIF image gallery of the build here:
imgur.com/a/zaMlH
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[@zyneil6827]

The author does like to from scratch, kzbin.infoUgkxbnOKZBE4evMO5V2vroHeCjq6d_MV6wJO shaping and trimming wood from large blocks into fine finished products. As another reviewer mentioned, most projects require a lot of high-dollar equipment that most of us don’t have the room or budget for. But, knowing how to do these things, even if we won’t be able to practise the full stack project, is still great.

[@paulodeoliveira3368]

This is a great idea. Although I wouldn't use the filler piece the simple yet beautiful tables are great as it's.

[@Dickie2702]

Great job! I've done tons of stuff like this in the past, mainly on custom boat interiors. Two for those interested in trying this. Thin kerf blades create fairer curves, less stress and fewer failures. Tip two, dont use regular wood glue, very poor gap filling properties. You should use epoxy, thicken it with wood flour and you are good to go, no filler or splints required.

[@nathangalvez9642]

Great video, I felt like i was meditating while watching it,

[@rotorage4374]

I just wish you would talk I hate video without talking. You're obviously a skilled joiner but hearing your voice and actually listening to your tips would have got me to subscribe.

[@bahijtaouk]

Simple and elegant. It's brilliant!

[@CamsWoodcrafting]

I really really liked it, and then you added the flush trim, not a fan, but otherwise very well done :)

[@BhaaskarDesai]

No stupid music, no blah blah.Just excellence~! Great work :)

[@LassetUnsSpielen]

stupid music is the worst. I'm sick of the ukulele

[@IanSmithKSP]

It looked like you said "ehh good enough" many, many times in this video.

[@Beyondrandom]

Very satisfying to watch. Always wanted to try kerf cuts. Subbed for sure!

[@TheJohdu]

awesome technique

[@zacharytatom283]

Great choice in pencils

[@cschoi100]

Beautiful and great idea! 👍

[@whiterussian6144]

Very nice!

[@Mary-fq6sm]

Beautiful work!

[@amineguellil6229]

Nice work

[@modernpolymath]

Man, that was a great video.

[@nathanjohansen7169]

3:55 - Honey, have you seen the table leg?! Uh... nope.

[@MGMakes]

Great functionality and clean aesthetic there pal. I love the idea of the bridging panel. Have a great 2018. 👊👊👊

[@curnowornever]

Totally DOPE!!

[@pwashcroft]

Very cool. I like the vinyl you put on the underside too. I wonder if epoxy for glue would be a little stronger? Not that what you did appeared weak at all.

[@roqueraulbouchet7865]

Excellent work ! I would like to ask you about the plywood you use, is it birch or some other type of wood, I tried a similar design and it was impossible to bend the plywood, it broke, it was not very flexible,regards

[@HKrayani]

Is it strong to be used as seat? Without the below part? So simply achieved the curve ; nice work

[@RealMangaAddict]

Nice build, but couldn't a single rectangle tabletop resting on the ottomans accomplish the same thing?

[@TheKraken123]

Nice work, but the result does not look convincing. If you don't connect the two table-things to each other it will sooner or later drift apart if you use ist. Also a little bit wobbly, i would not put a glass of wine on it.

[@giggidygiggidy4884]

I totally dig the ottomans but don’t see the need for the little insert piece, I just feel like it would fall between or eventually get lost. Also I don’t understand the need for the dry erase stuff. Is it just so it glides over the fabric better?

[@vooveks]

I was hoping the end piece would somehow lock the two together, or hide a pin that did the same. It would make sense then. Plus yeah, why the plastic sheet? To hide the joints inside maybe? The do look a bit janky, all covered in glue and filler. It's not needed for sliding, if the wood is smooth and treated. The trouble with those kerf cuts and why you'd want to hide them, is that it's almost impossible to make them actually look nice, I'd say, plus you've got the fact that the facets are really obvious on the bend. You can make them look 'alright', which he did, but in my opinion, bent ply has to be properly steam/wet bent in layers for the ends and curve to look good. Fine if you can't see them, but a bit ugly on display. You'd never see an equivalent commercial piece made like that, even a fairly cheap one, for those reasons.

[@JackCloudie]

@@vooveks The dry erase stuff is likely to let it slide onto the ottomans easier. What I don't get, is why he made two of them, rather than one long one to drop over top of two of the ottomans.

[@Sasquatters]

Giggidygiggidy for a modern look and functionality.

[@ryanpenir8253]

Very cool! Loved the pole sanding...that didn’t come out right...good job sanding with your...I’m just gonna quit...great build!!!

[@volundrfrey896]

I think I can help you phrase that. It's what really enjoyable watching him work that long hard pole into every nook and cranny.

[@DFWFishing]

Völundr Frey LMFTFY I enjoyed watching him use his long hard shaft to ream out that tight spot 😂

[@nickw9376]

Link to how many 3mm kerfs you need to cut for given diameter bend in Xmm ply?

[@FCAutos]

Very good content, and very cool approach on how you planned and filmed from the angles and edited the video. Good stuff...

[@leviathanx0815]

That's is a very neat little trick. Cutting stripes to bend it...I only saw people using hot steam so far... The result looks great as well. :D

[@davewilliams355]

That’s brilliant

[@yfm.mp4]

WHEN HE BENDS THAT WOOD I SCREAM! God it's so satisfying!!!!!!!!

[@dawei53]

Love the lack of music - I could concentrate on the video.

[@LizQuilty]

Loved all of this except that tiny joiner bit which just seemed to make it odd. Def something i'll be making though, i also have 2 really large ottos and no coffee table :/

[@dmthandmade5674]

This is brilliant. Craftsmanshio and no waffle. Your video of this technique has helped me with my DIY pedalboard. Thank you.

[@stuffsethmakes]

Very cool! I’ve been wanting to try bending with kerfs. Loved your little reinforcing splines. Not I’m pumped to try it. Great job, thanks for the inspiration!

[@CorinneyJ]

First it was nails, then cookie decorating, but now I’ve found my new favorite relaxation videos: WOODWORKING! (Beautiful pieces, too.)

[@Sevendogtags]

Nails???

[@CorinneyJ]

Sevendogtags fingernails! 💅

[@chipsterb4946]

This technique would make a really cool guitar amp cab. Thanks!

[@RexKrueger]

Outstanding! Very clear, even without narration. I couldn't do a silent video if you paid me money. Also, I wonder if you could do the glue-up with epoxy thickened with dark (walnut ) dust. Then the glue would be it's own filler and you'd get a nice contrast in the joint; kind of like an inlay. Just a thought.

[@joshmyer9]

I like the croissants you used, nice design work on those. (What else would you call a crescent shaped biscuit?)

[@chipsterb4946]

Josh Myer - yeah I was trying to figure out where he was going with those perpendicular cuts and then said AWESOME.

[@thunderoverwater1817]

I’m flabbergasted. Why did no one ever tell me that you could do that with plywood?! Im a girl, but still...I feel like this is a secret you guys were keeping from us.

[@charlesflowers3018]

USE A PUSH BLOCK! it really makes me cringe when I see somone using their fingers instead of a 'push block' to run small stock through the table saw. Cut off fingers can happen in literally an instant, and that will totally ruin your project. Something like this, kzbin.info/www/bejne/gH6mln2bfrSGfc0 Or even something simple will do.

[@McRocket]

Neat. Like the no talk/no music format.

[@tpopejr]

Very nice. How do you determine the distance between the kerf cuts?

[@tpopejr]

Found this: www.blocklayer.com/kerf-spacingeng.aspx

[@massimotartaglia8704]

Amazing

[@euricarogers1806]

OMG, this was very cool to watch. It helped me tremendously on my upcoming projects. Thank you kindly :)

[@sleepzzz800]

Just curious, why the extra cuts in the kerf cuts?

[@sleepzzz800]

Nvm commented too soon... lol

[@franciscoleonardo9934]

Awesome, but I think I will buy one because I will spend too much money buying tools😁

[@klaus2guck2raus]

Love it, great work!! How stable is the table? Could you use it as a seat as well? Or make a seat with this bending technique? Cheers!

[@kjellski]

Hey man, such a nice built and great explanatory video, you've got a new subscriber! :)

[@ypogyta7480]

Из 220 к просмотров только 4,5 к лайков? Это не правильно )

[@satman1w]

nice, i like it, but still trying to figure out the purpose of that insert between two tables...

[@juanduarte200]

Pero Perić, It looks like it has the purpose of creating a big center table

[@4.0.4]

I really loved the minimalist editing! Anyone with a heavy accent should learn how you did this instead. Not a single word, not even written, yet the good editing shines through. Easy to follow and neat technique. The end product is quite gay though. What do you do with that middle piece when you separate both halves?

[@chexstix]

Very clever construction. Thanks for posting!

[@hamp7803]

Where is the 'I LOVE' button on here? I only see the 'I Like', which isn't good enough(although I did click it).

[@uhfnutbar1]

I be missing a finger if i try this , no thanks :)

[@CoinWasher]

6:41 The noise with this speed-up makes me giggle. I'm given this image in my head of a small animal scampering around. Man this project looks so cool and relatively easy enough for the likes of a college student to build. Thanks for the idea, dude.

[@4mytoytube]

I love your work, but I want to hate it .... Only because I don't have the space to work on my own shit.. But again I love your work... Thank you :-)

[@joechabaks7733]

Looks good. That middle piece tho lol...kinda pointless

[@wadehammerstrom2685]

Nice job! Style of video is like Ishitani Furniture

[@umboccioni]

Awesome work but could have just put them side to side by orienting them 90% then wouldn’t have to worry about having the piece of wood around the living room. Just a thought.

[@layeredwork]

[x] subscribed Simple idea, minimalist design, well done! 👍🏻

[@vincentboulais2393]

Hi! I have a small question for you, is there a rule mixing the pitch of the cut, the thickness of the plywood and the radius that the wish to give to the panel? Thank you in advance, Vincent

[@Jason-jh9uv]

This doesn’t even look like a self made piece of furniture ( except the thing in between the two ). If I saw this anywhere for 50-100 I wouldn’t even think about not buying it because it’s such a bargain. Very nice work and the self adhesive film took it to a whole different level

[@gs-tr4si]

You have either left out some key steps or you are using a special plywood (it looks like 1/2 inch Baltic in the photo) because this is impossible with more than twice the number of kerfs in 3" space. So, what is it?

[@11SecSTionStockSnail]

Kerf bending is so popular that someone should make some inverted V shaped blades by now specifically for this purpose. (So when you bend/glue it, there’s no empty triangle looking spaces

[@MarinusVenter]

Very nice. But some idiot is going to sit on that...

[@thedarkmage1004]

Every time in the captions, it says "glamor" shots and I chant in my head *"glamour shots glamour shots glamour shots"*

[@Lycantherous]

great use of captions, however i wonder if its possible to put a sort of "this video contains no narration or music, captions are purely bonus material" statement at the beginning of them to help out d/Deaf folks better understand whats going on?

[@rickvanhooren548]

Awesome original plan and great build video...+1 subscriber...Cheers!

[@ashy7198]

what an awesome idea. I'd have made them slightly taller than the cushions so that they were the same exact height and fit the bridge a little more flush, but it still amazing :D x

[@jodytho]

nice and simple. straightforward, well-made video

[@drumunl]

Awesome project! Subscribed!

[@MelvinDlaCruz]

Hi do you sell this ones

[@johnharrison698]

Nice vid,beats steam box bending any day great job on the build !!!!!!

[@SynthVerseSounds]

Awesome work man..just add some voice over and the videos will be the million dollar ones...

[@CasualDIY]

Very nice project an a cool video, just had to subscribe to your channel :)

[@KaydenFox]

How did you calculate the placement of the cuts to obtain the proper angle?

[@michaelleiato1277]

What kind of stain did you use?

[@jasonb202020]

this is awesome ... best kerf cut tutorial on youtube ... 5 BIG FAT STARS

[@gXXrGoNe]

That was absolutely beautiful! Fantastic job.

[@Hailstormand]

0:44-0:47 Why do I find this part funny...?

[@Alistair]

I think it's because it's like a slightly shy shark or dinosaur popping up

[@nixcoolfix]

Cool Idea! Won't the corner brake soon??

[@andreaford9395]

Thanks so much for this! Exactly what I was looking for to solve a project!

[@YipWai]

Wow, this is the only way I don't need to steam it. I guess

[@rgrifat]

Nice. Why do you call it ottoman?

[@demonshaz]

Almost kickback at 5.29! Be safe. We don't want to lose another great man

[@RossRawlins]

what is that white laminate you put on the inside? and is that what its made for?

[@JosephClatterbuck]

Awesome build! I'm going to build one of these with shorter legs to go on the middle couch cushion. Also, I love the thematic shooting. Diresta would be proud.

[@rosscopiaco363]

What is that white laminate?

[@MacMcDell]

I am curious to know if these have held up to the gentle touch of children?

[@100nni]

Such a great video! Love the build. Could you please stop wasting so much glue though? It would really help my ocd

[@richardclarke9966]

Bloody genius! 👏

[@soapdude1]

Absolutely awesome!

[@Gsmith96]

Very useful! Do the stools push apart easily if you put any pressure on the joining strip?

[@MeasuredWorkshop]

The ottomans are so damn heavy as it is, it’s hard to tell how secure that joining strip is making the connection, but things seem pretty sturdy once everything is connected and in place.

[@ronmiller7248]

I'd sink a few neodymium magnets

[@jethro9341]

Im surprised to see 10 intact fingers.

[@tayyaratis]

Lean, Nice and Clean

[@DeathSoon666]

nice box challenge

[@joefentress7278]

absolutely amazing

[@stephenmeinhold5452]

and now you know why they use steam bending for plywood.