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Premium Member Comment by Matthys on November 18, 2010 at 7:58

ahhhh
i forgot about that steve!!!
good thinking...
yea radii

Premium Member Comment by Steve on November 18, 2010 at 4:40

Building a concrete mold how you desribed Mattys would create a mold that would not have equal dispersion of pressure. You cannot mold the male side directly from the female side as the width of the board needs to be accounted for otherwise radius's (radii?) of drops and concaves will be the same and they need to be different.

Thin plys lots and lots of pressure and I would sugest maybe a cut out or not much extra material around the corners of the foot platform of the blank as you could imagine this is where the greatest stress would be

Premium Member Comment by Matthys on November 17, 2010 at 21:47

i see what your saying fitz..
1.2 - 1.6mm veneer can bend into crazy shapes!!
the mold just has to have an equal dispersion of pressure that hugs all of the wood at the same time, if there was a gap in the mold where a lot of pressure was released, then it should be much more prone to snapping in the mold....

Premium Member Comment by Fitz on November 17, 2010 at 21:14

Shouldn't matter if its non linear or not. Your x-plys go against the norm anyway and every deck has them.
Like Jez said, thinner plys are the trick.

Premium Member Comment by Fitz on November 17, 2010 at 20:53

In the old days they used to use steam or presoaked veneers to make the wood more flexible and less prone to splitting. It's not as bad as you say but is alot of extra unrequired work for just making a deck.
It can lead to thicker plys if left untreated however it's normally used prior to going into a heated press with mega tons of pressure which compress it back to a thinner state.
Stick with dry plys for best homemade results.

Premium Member Comment by Matthys on November 17, 2010 at 20:25

jezza
you really really really really really really really really really really dont want to use steam...
it expands and bursts the cells in the wood fibers, making the wood not only heaps weaker, but thicker...
water and steam work with woods with little to no water content, such as balsa that have a very high percentage of air, with little real substance.

Premium Member Comment by Matthys on November 17, 2010 at 20:22

easy mate,
just get a male block of foam, shape to desired complex concave with rasps and planes and sanders and whatnot, then pour conrete onto the foam to get the female side of the concrete mold, then take out the foam, put a plastic sheet on top of the female concrete mold, then pour in concrete over that to have both sides...
easy as pie really..
just time consuming and a little expensive to start off with...

Comment by Matt Ryan on November 17, 2010 at 19:05

beautiful concave looks awesome

Comment by Jezza on November 17, 2010 at 19:02

really thin plys, steam and butloads of pressure.

Comment by H_Can on November 11, 2010 at 6:30

the jack in the press was about $100, the rest of it was another ~$500 and that was with cheap/free steel through work/trade-school.

the little strips on the drop-thru mounts were hacked off a broken chair, I need to find a better material so that i can make more of them without breaking chairs.

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