Oh the mysteries of bent plywood. We all want it, yet no one can make it. ”Do you use steam?” the people ask. “No,” we say, “we use genius…”
Step 1. Cut out your desired shape from some masonite board.
Step 2. Glue masonite to a huge piece of foam. Walk a few feet down to your local foam cutting shop.
Step 3. Cut that foam to match your template. We will call this the “mold.”
Step 4. Get some 1/8” or thinner sheet of birch or whatever kind you want. Cut this down to create about 4 or more strips to fit your mold.
Step 5. Cover the strips in glue and layer them on the mold. Then put the whole thing in a big vacuum bag and suck all the air out of it.
Step 6. Trim the edges of the wood after it dries. Here it is- your bent plywood form just like you always wanted.
