Building a Beautiful Bentwood Bar Cart - A Woodworking Challenge

TLDRWatch as I take on the Rockler Bentwood Challenge and create a stunning bentwood bar cart. I start by designing the cart by hand, cutting out the curves, and smoothing them. Then, I create a bending form and bend the wood to shape. Next, I attach the two halves and template route the entire cart. After that, I prepare the maple strips and glue them together to form the base. Finally, I trim and shape the cart, creating the curved handles and adding the finishing touches. The result is a beautiful and functional bar cart that showcases the beauty of bentwood.

Key insights

🔨I designed the cart by hand and laid it out full-size on butcher paper to get a sense of scale before cutting anything.

🔥I used a vacuum press to bend the wood for the cart, resulting in beautiful curves and a strong structure.

💪I made my own bending form by attaching two halves of MDF and template routing the entire form for precision and stability.

🛠️I created a router jig to cut the curved half-lap joinery in the base of the cart, ensuring a secure and seamless fit.

🎨I added a unique curved profile to the base of the cart, enhancing its aesthetic appeal and showcasing the beauty of bentwood.

Q&A

What materials did you use for the bar cart?

—I primarily used maple wood for the cart, as well as thin paper-backed walnut veneer for the trays.

How did you bend the wood for the cart?

—I used a vacuum press to bend the wood. The atmospheric pressure compressed the layers onto the bending form, resulting in the desired shape.

Did you make any custom tools or jigs for this project?

—Yes, I created a bending form by attaching two halves of MDF, as well as a router jig to cut the curved half-lap joinery in the base.

How did you achieve the curved profile on the base of the cart?

—I shaped the transitions between the curved half-lap joints by hand, creating a unique curved profile that adds to the beauty of the cart.

What was the most challenging part of building the bar cart?

—The glue-up of the bentwood panels was the most challenging part, as it required precise alignment and quick work to ensure a strong bond.

Timestamped Summary

00:14Introduction to building a bentwood bar cart for the Rockler Bentwood Challenge.

00:40Designing the cart by hand and getting a sense of scale before cutting anything.

01:58Using a vacuum press to bend the wood for the cart, resulting in beautiful curves.

02:09Creating a custom bending form by template routing two halves of MDF.

04:43Trimming and smoothing the curved panels of the cart.

10:41Preparing the maple strips and gluing them together to form the base.

18:01Shaping and adding a curved profile to the base of the cart.

20:03Creating a router jig to cut the curved half-lap joinery in the base.

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