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Super sized DIY cutting and pressing table - #IKEAhack Step 1: prepping the Kallax sandwich
In my last post I explained how I designed a huge cutting and pressing table to go in my sewing room.
My design involved sandwiching four Kallax units between two layers of MDF board - the base board and the top - giving lots of strength for a fairly small weight (a bit like a marshmallow and wafer biscuit😁).
But first I wanted to check exactly how I wanted the units to be laid out. This took me quite some time!!
💪Top and base board
I went with 18 mm MDF in a structural grade for extra strength - it has more layers than normal MDF. This is rather heavy stuff but I wanted to be sure both the base and the top wouldn't bow, especially as I had a lot of voids and cantilered overhangs. I used two standard size sheets (1220 x 2440mm) - bought and delivered from a local builders merchant as no way were they fitting in my car!
To get the wood into my attic room, I needed to cut both base and the top in sections and fix them back together as I built the table. But I needed to work out the best way to do this to minimise the number of cuts and unusable offcuts, and give the most stability to the sandwich.
I had already decided the top needed to be 1.4m wide and as long as possible - see "wish list" in my last post. The base just needed to be big enough to fit the Kallax units on.
I used my trusty spreadsheet again as graph paper to play around with options - this is the final version. The graphic shows the different layers on top of each other, but upside-down.
- The bigger gold rectangle is the top board, and the darker brown strips are a wood frame supporting it.
- The ikea units are the pale yellow rectangles.
- The white rectangle is the base board, with red castors and some wood supporting strips.
The sheets were cut with a rotary saw using a long piece of wood as a straight edge guide - it took 3 of us and lots of clamps. A table saw would have made it a lot easier (maybe this year's birthday pressie!). I guess it is possible to do with a hand saw, or you could look for a supplier that will cut it to size for you.
Will it work?
Checking the top out for size |
My construction method involved adding the top last (more later), but I wanted to check it would work.
I put the units in place exactly as I wanted them (in hindsight this would have been easier if I'd actually laid them on the base boards 😏 ), and placed the top boards on the units. This way I could make sure I could actually reach the middle from the side, and check the overhangs at each end were sensible.
You can't see from the photo, but the front
overhang is shorter so I can easily reach into the cubes, and the back
is longer so it fits over other furniture to get it out of the way when
in bedroom mode - see planning.
The spaces between the units are deliberate - as well as making the base that bit bigger and therefore more stable for the huge top, I have plans for to use them for storage accessories!!
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