"Working with Plywood"
5-DVD Boxed Set
I had my “ah-ha” moment when I watched your DVD. I know when people watch this they will get a ton out of it. And of course, as always, you have some bonus footage in which you demonstrated a technique using a stopped dado router jig and you show how to build that. That’s fantastic.
As always, you put a ton of detail into this. Many DVD producers out there only really hit the highlights. They mention things and then say you can either visit their website to learn more or you can look it up yourself. I like the way you go through and add the detail that needs to be there to explain why you do things. That’s just fantastic.
The way I’ve always described your DVDs to people is that it’s like you’ve made a personal trip to someone’s shop and you’re standing right there with them. That’s the way that it plays and I think that’s perfect. I like the way you do this and that’s one reason I highly recommend it to people.
When it comes to the Table of Contents, and the way the DVDs are laid out, you can sit down and watch the 11 plus hours if you wanted to, or you can break it down step by step the way that you would normally work on your project. The person who is setting up a project can follow along on this DVD and follow those steps that you’re laying out there. I think that’s great.
What I really liked was watching the dry fitting because that’s something that I think a lot of people skip over. Now a dry fit is a huge part of any project that I’m working on.
There are some things you just have to see to really have it sink in. Like I said, I had several “ah-ha” moments. I highly recommend this DVD. I can’t recommend it enough.
-- Matt Vanderlist
Host of Matt’s Basement Workshop Podcast
For larger projects the use of plywood saves the time and effort required to plank up large panels and can provide the same strength and appearance at a lower cost. However, as Hendrik Varju explains in his DVD set, Working with Plywood, there is much more involved than just substituting plywood for solid timber.
For cabinetmaking applications plywood cannot be effectively jointed or planed. Components must be precisely cut on the table saw and routed to shape as required. You have to learn how to work with slightly bowed panels and inconsistent sheet thicknesses. The edges need to be covered by iron-on veneering or solid edging. A number of specialized skills are required to be able to work successfully with plywood.
Hendrik Varju has previously released two DVD sets, Jointer and Planer Secrets, and Revelations on Table Saw Set-Up & Safety. If you have purchased either set, you will be familiar with Hendrik’s video style.
The DVDs run as if you are attending an actual one-on-one workshop with Hendrik at his woodworking premises, Passion for Wood, in Erin, Ontario, Canada. Hendrik conducts numerous classes and produces these DVDs as a means of spreading his instruction to a wider audience.
As with the previous topics, the footage on Working with Plywood is lengthy – 11 hours, 18 minutes spread over five DVDs. While not inexpensive, Hendrik’s DVD sets provide excellent value as they go into their topics in great depth. In effect you receive one-on-one class instruction without paying for the full cost of the class, nor the airfares and accommodation.
Another benefit is that Hendrik’s DVDs cover subjects that have not been extensively covered by previous publications or videos.
When you open the DVD case, don’t panic if you don’t see DVD1. I found it attached to the front cover, hidden behind the Table of Contents. This is a single sheet that lays out the chapters and the DVDs on which they can be found. While the chapters appear on the menu on each disc, it’s handy to be able to locate the correct disc before inserting it into your DVD player or computer.
To demonstrate the basic skills and steps required to successfully build with plywood, Hendrik constructs a simple bookcase with two shelves. As he explains, it’s not the most exciting project, but the same techniques can be applied to much larger and more complex cabinets such as entertainment units, wall units and kitchen cupboards.
The bookcase has veneered plywood panels finished with both solid timber and iron-on veneer edging. Some smaller components are cut from solid timber to illustrate how veneered plywood and solid timber can be matched together in a completed piece.
The first chapter on Planning Your Project covers the type of construction used, the reasons for various conventions and what you should consider when designing your own pieces, preparing the cutting list and marking out the plywood for cutting. Much of the information in this chapter can be applied to any cabinetwork, irrespective of whether plywood is used.
In Choosing and Roughing Out Parts Hendrik discusses plywood selection, what defects to avoid and the importance of the correct blade. The sheet is then cut into oversized components on the table saw.
Solid Wood Edging covers the ripping of solid stock into multiple edging pieces, with an emphasis on safety and accuracy. The strips are then glued onto the plywood panels. In this process, care must be taken with colour and grain matching, positioning, clamping and trimming. Included are a number of professional tips on how to overcome problems that inevitably arise.
The Iron-on Edge Banding chapter refers only to the use of genuine timber veneer, not to artificial iron-on edging. The final result is a veneer similar to the outer veneer on the plywood. Again there are a number of tips to assist you to achieve a perfect finish.
With the exposed edges trimmed, the panels are trimmed to their final size and rebates routed for the shelving and back panel.
To form the rebates Hendrik makes good use of his stopped dado router jig. In Chapters 11-13 he details how you can make your own copy of this jig.
Further chapters cover dry assembly, drilling shelf support holes, final glue-up and the installation of adjustable shelves and the back panel.
Housed joints and dowels are used for assembly. The section on dowelling is quite extensive and offers many tips on making these joints easier and more accurate.
In extra footage (about 15 mins) on Disk Five, Hendrik discusses the use of plywood versus solid wood, checking for square and his personal philosophy on why he puts so much detail into his DVDs.
Working with Plywood is a comprehensive workshop on the construction of a basic cabinet unit. It is an excellent introduction for the novice while providing a wealth of tips and information to enable more experienced cabinetmakers to enhance their work.
-- As reviewed in The Australian Woodworker Issue 151
I have viewed all of your video instructions and learned more from them than any book. Sure wish that you also have a bandsaw video upcoming soon.
No objections using my comments [on your website] but it may be better to emphasize that Hendrik's videos show how to do cutting/milling and other operations in much detail vs just showing what to do.
I have purchased all of the videos and am looking forward to any others that will be made. Thanks again . . . still learning even after watching the dvds over 3 times!
-- Calvin H. (Waipahu, Hawaii, USA)
It's like Christmas!! I've been waiting for another title to come out, and you release two titles!! Without a doubt, your videos are the most comprehensive and useful videos available (and I have many other videos). I refer back to them often. Thank you!!
-- David R. (Plano, Texas, USA)