Holding It All Together…

Now that the leg assemblies have been completed it is time to attach them to the table top.  The solution that we have chosen to make this happen is to create a lightweight yet very strong torsion box.  The box is constructed very much the same way a “hollow-core” door is made.  The legs will then be bolted to the torsion box.  Below Austin begins the work of creating a flat and level working surface to create the torsion box.

The box will be constructed of 2 sheets of 1/4″ baltic birch plywood, honeycomb cardboard and solid maple frame members.  All of these pieces will be glued together and clamped in a special vacuum bag.  Vacuum pressure will actually hold and clamp the box while the glue dries.  Because of the size of the torsion box.  We will need to fabricate a special bag.  We will be using thick mil visqueen plastic (shown below)and special caulk

Next Austin and Jacob attach the solid maple frame members that will make up the outside edge of the torsion box


Many clamps are used to hold each piece of the frame as it dries in place


After the frame has been attached, and the honeycomb cardboard panels are cut to fit within the frame (see white panels below)…the leg assemblies are positioned on the box to determine where the solid maple reinforcing block will be placed


Next the maple blocks are cut and fitted into place.


Then all of the other torsion box components receive a layer glue and are placed in the specially made vacuum bag.  Below Jacob has to arrange some of the pieces in the bag.  Remmert Studios assistant Don Macaluso (shown holding the bag) says that Jacob really enjoys “getting into his work’.


Finally the bag is under vacuum pressure, and Jacob inspects the seam massaging out any leaks.


Coming soon…. the table gets its legs…. and takes its first steps……








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