Twisting Luan

[Stwood_]

Since you've posted that where-it-goes pic, lets change direction a bit.
How about a rectanguler piece of 1/4 ply, big enough to hold it up over that hole.
Hold it against the hole in a couple of places, then eyeball the open places where the ply doesn't cover.
Fashion some filler blocks from say 1/2 material (bandsaw/rasp) and fill those holes in, attaching those pieces to the existing trim you have there.
Then simply attach the rectangular piece of luan onto those 4 pieces of filler block.

[MsNomer]

That was my first thought and is still my fallback if my bending doesn’t work. The downside is that I would lose the curve of the corner. I have worked hard to preserve the curves so that the space still looks like a vehicle.

[jteneyck]

Maybe carve a block of foam to fit, then cover the face with resin and fiberglass.  Paint to suit.  

John

[MsNomer]

I’ve contemplated whether I could carve a block of wood. That would certainly be a major test of my skills. However, when I hold the paper template at a certain angle, I see a simple curve…

[Stwood_]

Mount a cargo light there after you get a flat corner there......

[MsNomer]

My first attempt was both a success and a failure. I boiled a piece of Luan for 15 minutes, testing after each five. The failure was that the back ply started coming apart. The success was that the rest held together and the bend was totally adequate. Next I will steam it instead of soaking it. It might actually work to completely separate the ply into its three layers, sand them lightly, then glue them on one at a time in place. Each end will have a screw in it that would hold the assembly while the glue dries.

[mike4244]

I know Luan is perfectly capable of twisting without any help from me, but I need to control the twist.  This is a trim piece for the van. The entire piece is a bit more than five feet long and 2.25” wide.  It needs a twist at each end to curve around and join the side 45° "crown molds ".   The twist is about 45° from the plys.  This template approximates the final shape with the shaker holding down what will be the long center part.  The twisted ends will be screwed to the crown mold.



I can’t easily make a jig.  My plan is to wet the back side, force it into shape, and screw it down til it dries, then remove and paint both sides.

Any words of wisdom?


Heat a pot of water til it simmers and add fabric softner. I use Downy. I generally pour the entire bottle into several gallons of water but I think you may need a couple of ounces in a 4 quart pot. Turn heat off, add softener and hold the end in the pot for 10 minutes. You should be able to twist the part like a pretzel if you want.
I have done this with solid wood but not plywood. 

mike

[MsNomer]

I will be trying that today! And I never thought of using solid wood. I could do that. Thanks.

[brianwelch]

I will be trying that today!  And I never thought of using solid wood. I could do that.  Thanks.

https://philadelphia.craigslist.org/mad/...70519.html

Not sure if there is a source of this product near you...

[MsNomer]

Well, I didn’t try it yesterday.  Instead, I improved the underlying boards.



The outer edge of that is paper-thin as it goes around the corner.  The Luan on the left is still just a template which I hope to replace today.  That cutout on the end was to make it fit into the corner until one day I saw it had warped a bit and realized the curved corner was a possibility.  
  Serendipity is still in full swing.