Boiler Cover

Tuesday 07 October 2008

Alan Holtham shows you how to use bendy MDF to cover in a boiler

1.The finished boiler cover, primed with thinned down undercoat and finished with two coats of gloss

Although they are getting smaller and neater, central heating boilers could never be described as elegant, and then all the associated electrical and pipe work makes them look even worse. I was recently asked to box in a particularly unattractive one which was mounted at floor level, leaving the top fully exposed. The brief was to produce a design to cover up the boiler, but at the same time minimize the amount of space taken up in the already cramped room.

Easy access

From a plumber's point of view it is important that the boiler can be serviced easily, and a close fitting cupboard makes this job a nightmare. The recommendation is to leave at least 6" clearance all round the boiler, but the room was just not big enough for a cupboard of this size, so I settled on a much tighter design that was freestanding and could be easily removed. I did incorporate a small door so that the controls and filling loop could be accessed without moving the whole cupboard.

Bendy MDF

The answer came in the form of bendy MDF, which is available in 6 mm thick sheets. One face is cut with a series of regularly spaced fine grooves, resulting in a very flexible panel. This can be bent to quite a tight radius and seemed ideal for this purpose, although I must confess that I had never used it before, so the whole job was going to be a literal learning curve!

These bendy MDF panels are relatively cheap and easily available in 610mm widths from most of the big DIY stores. It is produced in much bigger sheets, but I was not able to source one in time, so had to use smaller sheets. In retrospect the job would have been much better if I could have formed the whole shape in one larger piece.

The mould

To form the curved panels, make a mould with pieces of 12 mm MDF, cutting out three equal rectangles to match the size of the cupboard footprint; cut them carefully as they will be used subsequently as top and bottom boards in the actual cupboard.

Glossary Rollover a term to view its definition

  • Router
     

    Router

    Router

    Most routers are plunge type, which means the motor body is plunged to allow the cutter to enter the workpiece and make the cut. There are a few fixed body types which are normally pushed into the work from the end of the workpiece as the cutter is already projecting beneath the baseplate. Routers use special high-speed carefully balanced motors that drive a spindle in which a collet is fitted at the bottom end. The spindle runs in special high-speed bearings and the collet can be interchanged depending on what cutter shank size is in use. A collet is different from a chuck in that it can only hold a specific shank diameter whereas a chuck can be adjusted to suit any diameter within its range. The collet is the most critical part and the best machines have much better more reliable collets. This is important as cutting speeds can be as high as 27,000 rpm depending on the cutter type and size. Routers work best with some means of guidance such as a fence or guide bush.

     
  • Tablesaw
     

    Tablesaw

    Tablesaw

    The tablesaw offers a means of both rough and precise sawing of timber quickly and efficiently, depending on the blade used. Smaller machines are limited in capacity but larger machines may be able to process large panels and dimension stock to length when crosscutting. It is essential to have at least two different blades, a rip blade for fast cutting of timber and a crosscutting blade for more precise cuts especially across the grain of the timber.

     

top tips

On a safety note, it is important to check that the boiler you intend covering is in fact suitable, as many of the older types require free air circulation in order to operate safely and it is extremely dangerous to restrict this air flow by enclosing them in a cupboard. Most modern boilers are fitted with a double flue, which draws in all the air it needs and exhausts the fumes through the same pipe. These boilers are classed as 'room sealed' and can be safely boxed in. Get qualified advice if you have any doubts.

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