Hello, this is about weight – weight of the finished product.
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I am increasingly using MDF in my cases since I like to do a lot of marquetry. The problem is that the finished product becomes so heavy that it is hard to handle and move.
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I looked at honeycomb material the other day and wondered how it would be to use it with a ¼” or thinner, MDF on each side. The edges can be made from solid wood for fastening hardware etc. Has any one out there gone that route or is it a crazy idea all together?
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Stig.
Replies
Stig,
What you are describing is most commonly seen in hollow core doors, so it is definitely a viable idea. The biggest technical problem is in evenly clamping the core/facing sandwich together while the glue sets, using a vacuum bag is a common approach for larger areas.
John W.
Stig,
Aircraft practice is to use honeycomb anytime the private jet needs fancy woodwork..
There is ultralight MDF which is about 1/3 the weight of regular MDF.
It's actually more common but highly specialized. In the aircraftt industry as a fellow poster noted it's routine and typically lightwight high strength aluminum honeycombed panels are used. This is also torsion box related. Thinner skins with a thicker core is much stronger and more twist resistant. You can also get honeycomb core material from cardboard like in hollow core doors to plastic and aluminum. Obviously the aluminum is the most expensive. Go to the forum at http://www.vacupress.com for more honeycomb info. There's very little new technolgy in woodworking and by the time it trickles down to this level it's been around for40 years in industry. Vacuum pressing goes back to the 30's. Slot mortisers date to the 50's. Veneering and plywood go back to ancient Egypt
http://www.azom.com/details.asp?ArticleID=1092
Do a google search on honeycomb material sources.
Edited 8/9/2006 8:47 am ET by RickL
There is another product you might be interested in. This is plywood wth outer faces of mdf. I've been calling it armor-ply but it's marked "armor-plus" on the edge of the sheet. The sheet isn't marked with the manufacturers name. This is a great product for veneered furniture and cabinets. It's got the strength of plywood but the smooth face of mdf. I don't have a long history with the material, but so far I like it a lot. A sheet of 3/4mdf is just too heavy and I don't like the dust.
It's also called combined core. Certainly cheaper in the long run compared to honeycombed material.
http://www.taunton.com/finehomebuilding/pages/h00016.asp?
Thank You guys, good ideas.
I called around today and found to my dismay that no one in the lumber industry here in San Diego North County knows what I am talking about.
Since I have a full set-up from Vacu-Press I shall get hold of some honeycomb material and make some tests on flat and curved panels. I'm thinking about making a web frame of sorts with runners where I would put glides and other hardware. The web frame could be made of inexpensive wood except on the exposed edges. Veneer is really not that expensive and it is fast when you get the hang of it.
I'm suffering from a herniated disk as a result of lifting too heavy stuff, too many times in my 75 years on the planet. So, I got to find something light, and soon. I'll keep you guys informed. Thanks again.
Stig.
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