Two types of plywood were used. An top oak veneered 5mm plywood and a ‘regular’ 4mm cheap plywood.
The mold was made of birch plywood as you can see in the picture. The making of the mold has not been documented but it should be said that it started of as a 90 degree angle mold. A test piece was molded first. Once the molded part is removed from the mold, it flexes back a few degrees to an angle larger than 90 degrees. This needed to be measured and once this took place, the mold was reshaped to cater for this particular flex angle.
For the actual molding of the plywood pieces a rubber mat was used underneath so as to protect the working surface from the glue. Yellow glue dries very quickly.
From the plywood strips that were used, the inside one, the one with the smaller radius was notched so as to relieve some tension and facilitate cold bending. It turned out that one or two strips of the inside ones were cracked during bending but the tremendous pressure of the clamp together with the glue used, were enough to mold the entire array into a single body with no problems whatsoever.
After demolding, the pieces were cut to shape and formed round at the edges. Holes were drilled for the bolts to go through and countersink holes for the bolt heads and washers.
Then came sanding and varnishing using a water based clear varnish.
Of you have any questions about design or building this coat hanger then please send us an e-mail and we will be happy to help.