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- Trace All the Circles. The first phase of this project is to build the forms. The bendable plywood needs a structure to hold its shape. In steps 1-5 I'm building two forms, one for the inner shelf unit and one for the cabinet unit.
- Divide into Three Equal Slices. Dividing each disc into three slices (like a pie) helps align the discs when you build the forms. Draw a line through the center, then a perpendicular line through the midpoint of the radius.
- Cut Perfect Circles. You can cut perfect circles with a compass jig. To attach the router to 1/4-in. plywood, start by removing the baseplate and using it to trace the holes onto the plywood.
- Glue and Trim the Discs. Glue the inner discs to the top and bottom discs, centering them using the lines that divide the discs. The top and bottom of the shelf unit are identical, with the top/bottom discs larger by at least 1/4-in.
- Connect the Discs. Join the tops and bottoms of the cylinders with form spacers. I cut three pieces (F) sized for the shelf unit and three more (E) for the cabinet unit from 1x6 boards, then drilled pocket holes on both ends.
- Cut the Bendable Plywood to Length. For the next phase, steps 6-13 I'm wrapping bendable plywood around the forms. The bendable plywood fits between the top and bottom discs on the shelf unit.
- Fasten Stiffeners. Staple and glue stiffeners to each end of the bendable plywood. The stiffeners are cut to fit between the tops and bottoms of the shelf and cabinet units to prevent the plywood from bowing while you bend it around the forms.
- Bend the Plywood. I temporarily screwed the form to my work surface. Brush glue on the edge of the top and bottom discs. Work in small sections and flex the plywood tight to the form as you staple it to the sides, alternating between top and bottom.
- Add a Second Layer. The shelf unit needs only one layer of plywood, but the cabinet needs to be sturdier so I added a second. Mark the length of the second layer by clamping one end of the bendable plywood flush with the opening and bend it around to the other side of the opening.
- Layer Edge Banding. I used a technique called “bent wood lamination” to cover the exposed plywood and build up the opening to match the rest of the cylinder.
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