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Following on from this thread http://singletrackworld.com/forum/topic/birch-ply-kitchen-island-project-any-woodists-here-with-suggestions
I purchased 3 sheets 36mm thick birch ply for the project in case of errors. I had one eye on a matching kitchen table if all went well and I didn't dribble into the 3rd sheet. The island looks ace - and thanks to those who contributed on the thread. One or two suggestions I used, and a lead which meant the material came in under budget. So big thanks. Now onto the table.......
The top has been routed to size, 2200mm x1000mm, but at 36mm thick it's blinkin' heavy. Is there any way of easily getting rid of excess material from the underside, but leaving the edges at 36mm deep? As if I'd done it the logical way with 2 x 18mm sheets and just glued pieces all the way round the edge to give the appearance of 36mm!?
Does that make sense? Any ideas short of routing out the whole lot? Any ideas for a tool/type of workshop which could make light work of the job?
Cheers in advance!
Beagle
The time to do it was before you glued it, but you know that. To do it properly you'll need to router out pockets. That'll take ages by hand or be expensive on a cnc router. You could just router outlines and peel the middle bit out. The laminations won't be held together that well. Will leave a messy finish but it won't be seen.
Rougher out the border then set a circular saw to the same depth run a load of parallel lines close to gether being careful not to go outside your routed markings. Hit the now rooted bits sideways with a hammer and clean up.
do you need to make it lighter? Seems like a lost of hassle.
But what I would do is cut rectangles with a circular saw on the under side and then chisel out the rectangles.
Is there anyway you could chop enough out to use an electric plane?
Or a milling router bit http://www.axminster.co.uk/axcaliber-milling-cutter
Considering the work required I wouldn't bother. It's not like your carrying it around with you. Once it's in and installed it's done. Two good men to lift is all you need and is less dusty.
+1 don't bother.
I'd be slightly concerned about the ply warping over time.
Leave it alone.
If you start chopping bits out of it, you'll lose some of the stability, and unless you lovingly rout it out, you'll never get a decent finish.
As you've already said - the better way (if you needed it to be lighter weight) would have been to build it up from either 2 x 18mm or 3 x 12mm sheets.
Cheers All. Much appreciated. I may leave it be. Never considered the warping issue if routed/cut out. I may have to reconsider the leg support then and choose something sturdier. I just ordered it in the same spec as the island thickness. Probably didn't consider how heavy it'd be!
Any cheap steel leg suggestions?!! 🙁
Ditto on the removing material potentially causing stability and strength issues.
Try [url= https://www.etsy.com/uk/market/metal_table_legs ]Etsy[/url] for some legs?
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...or get a welder to make you up some legs, wire drill brush and lacquer...