| The first task is to cut the MDF to size on the table saw. I made mine 295mm x 210mm. Then rip some strips of walnut on the bandsaw to approximately 3mm thick. Next, plane off the saw marks from both sides with a block plane. |
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| Then it's time to glue the walnut strips to the edges as a hardwood lip. You could veneer the edges but I decided to use thicker timber as it would be stronger and chip resistant. |
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| Apply plenty of glue and clamp a pair of lippings to the MDF. I did one pair at a time to ensure proper alignment. |
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| Once dry, plane the edges down flush with the MDF
and trim the end to size. Then you can glue on the final two
sides. I was surprised how long it took me to glue up all the mats. There are six mats and you have to glue half a mat at a time. That's twelve glue-ups and it took a couple of weeks to complete them all (as I only get spare time in the evenings). |
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| With all the boards lipped and trimmed flush, it is time to cut the veneer to size. I used figured walnut for the tops and some off-cuts of maple and cherry for the bottom (unseen) surface. Cut them about 10mm oversize using a straight edge and a knife. |
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| With your veneer ready to go - it's time to prepare for gluing. I find it difficult to get even coverage using a brush or a squeegee to apply the glue so I have started using a mini-roller and tray. They cost around £2.00 but as long as you wash them out each time, they will last for ages. |
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| Roll on an even coat of glue (I've used a PVA). Don't put on too much or it will bleed through the thin veneer, spoiling the look. Put the backing veneer on and turn it over. Apply another coat of glue and put the top veneer on. |
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| Next, pop it in the vacuum press. Twenty minutes later - it's done. Then, stand the mat on its edge to allow it to cure overnight. |
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| The next job is to remove the excess veneer. This is a tricky job as you can easily remove too much, ruining the piece. I used a very sharp chisel and knife to slice off the excess and then used a plane to smooth the edges (including the walnut lipping). |
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| I then gently rounded over the sharp edges with some 240 grit sandpaper. |
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| When all the mats are veneered, its finishing time. I was eager to see the wonderful figure of the walnut spring to life! I applied a coat of sanding sealer with a brush and then sanded it smooth when dry. |
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| Spray time! I applied three coats of Chestnut Melamine Lacquer with my budget HVLP spray gun kit. I left them overnight to dry then sprayed the undersides the same. |
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| The next day, I gently sanded the top with 320 grit sandpaper and applied one more coat of lacquer. Set aside to cure for two to three days. |
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| I stuck some self-adhesive felt sheet to the
underside of the mats to stop them sliding when in use.
That completes the project. The figure of the walnut is just amazing! And the "customer" is very happy.....roll on meal-times. |
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