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Another End Grain Board Build.....

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Blog entry by JL7 posted 09-15-2013 02:19 AM 3039 reads 49 times favorited 37 comments Add to Favorites Watch

I’ve seen people posting boards with diamonds and thought that was cool…..I built a diamond board a few weeks ago HERE... and I just finished this one today:

So this blogs covers today’s board…

For a change, I started with some nice wide timber. No scraps in this board. This is Yellowheart and Tigerwood:

Cut into 1.5” by 26” strips (but I should have made them a bit longer). I don’t plan real well on the front end….4 of each color.

“V” cutter bit in the router table:

Cut V’s into 2 strips of each color:

Cut one square profile of each color – they were much larger than they needed to be but easier to square up, and it really helps if they really are square for the next step:

Glued up the same colored strips with the opposite colored square profile:

Forget to film, but ripped each of these down the middle of the square profile on the band saw to be planed later.

Next up, ripped some 5/8” square profiles that will be turned into dowels using the Veritas Dowel and Tenon cutter:

Here is the cutter in the vise:

Plus a couple shots of the process:

And a video of the dowel cutting HERE.

Put a 1/2” Round Nose bit in the table:

Cut half rounds in the other 4 strips:

Test fit with the dowels:

Glue the dowels in the half rounds:

Forgot to film, but now all the strips (round and diamond) are run thru the planer. And if you followed all of that, you will have 4 sets of shapes to glue up. Only glue each pair together, not the whole set:

Not shown, but the strips are cleaned up in the planer…...just be sure you keep everything centered! Then each 26” strip is cut in half…...now there are eight:

My first inclination was to glue them up in this configuration:

But in the end, I glued them up this way:

Also glued the Padauk “border” piece on the outside and left them long to help prevent snipe for the next step…...flatten it out, but easy does it here, take shallow cuts:

I use the radial arm saw because I get real square cuts, so here is the squared up blank:

I was originally going to cut 10 strips out of the blank, but they were just a little to thin (should have started with longer boards!) so I cut 8 strips and they were a bit thicker than I would normally cut (about 1.6”). I have a jig for the RAS for cutting these:

I was hoping to get this pattern which alternates the shapes in both directions, but the grain doesn’t match up that nice:

Also could have done this, which alternates color more:

This was the final choice, right or wrong:

I think this next step is really essential for a nice glue-up…..run the segments over some PSA sandpaper on a flat surface (MDF here). Use pencil marks and sand until they’re gone:

The parts should be tight without clamps:

Test clamp everything before the final glue-up…..I needed a few shims because things don’t always line up on there own:

To speed things up for glue, I flip all the glue faces up and clamp them together lightly and spread the glue on all of them at once:

Because this board has a border on it, I had to cut little pieces of Padauk to finish the border on the last 2 sides of the board, use the the same setup in the RAS so the height is the same:

These little bits were all cut to the same width of the strips so there is 8 little pieces to glue to each side…...kind of a pain, especially if you want to keep track of the grain and locations…...I ended up using wide blue tape to keep them in line, which also made the glue-up pretty simple:

If you are lucky enough to have a drum sander, fire it up. Mine is half home made, but works good:

Not shown, squared up all four edges on the RAS.

I used the chamfer bit for this one:

I was able to get the bottom side chamfered really close to the transition point where the border meets the main board:

Still needs tons of sanding…....8 grits with the ROS:

Mineral oil:

I’m sure you bailed long before you got here, but if not, thanks for looking…....

-- Jeff - I have not failed. I've just found 10,002 ways that won't work.



37 comments so far

View pneufab's profile

pneufab

103 posts in 1731 days


#1 posted 09-15-2013 02:40 AM

Awesome! I enjoyed reading the steps! Thank you!

View waho6o9's profile

waho6o9

4910 posts in 1227 days


#2 posted 09-15-2013 02:54 AM

Thank you for the fine pictorial!

Good job.

View whitebeast88's profile

whitebeast88

3524 posts in 841 days


#3 posted 09-15-2013 02:57 AM

very nice,thanks for the info.beautiful board.

-- Marty.Athens,AL

View DIYaholic's profile (online now)

DIYaholic

13503 posts in 1325 days


#4 posted 09-15-2013 03:06 AM

Bail???
I went and watched the dowel making video.
Ok, I also went to the fridge and got another cold one!!!

Great write up. A very well documented build process. Pictures do say a thousand words, but your text brought it all home.

Thanks for going through all the effort, to provide a great tutorial!!!

BTW: Where is the MAPLE??? ;^0

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View Mainiac Matt 's profile

Mainiac Matt

3982 posts in 979 days


#5 posted 09-15-2013 03:09 AM

thanks for detailing the process Jeff….

It’s quite ingenious.

-- Pine is fine, but Oak's no joke!

View patron's profile (online now)

patron

13033 posts in 1992 days


#6 posted 09-15-2013 03:12 AM

no bail

just hail

to a well done work
and tutorial

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Dusty56's profile

Dusty56

11657 posts in 2338 days


#7 posted 09-15-2013 03:39 AM

I have sooo far to go in this craft…thank you for all of the details and photos : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Kevin May's profile

Kevin May

65 posts in 965 days


#8 posted 09-15-2013 05:35 AM

Thanks for posting. It is a beautiful piece.

Because of your great care in creating a detailed post, I have only one question, how much time do you have in this project?

-- Kevin May "Making wood useful and fun!" www.kevinmaywoodworks.com

View fernandoindia's profile

fernandoindia

1073 posts in 1594 days


#9 posted 09-15-2013 05:37 AM

not just cut and glue. great job Jeff

-- Back home. Fernando

View Hawaiilad's profile

Hawaiilad

1985 posts in 1671 days


#10 posted 09-15-2013 06:44 AM

Jeff, that is a Great looking board and I thank you so much for the picture walk thru

-- Larry in sunny and warm Hawaii,

View SPalm's profile

SPalm

4806 posts in 2532 days


#11 posted 09-15-2013 11:54 AM

Great post Jeff.
Really good stuff in there.
I agree, take the time to make everything fit perfectly without clamps. And then add the clamps.

Very nice looking board,
Steve

-- -- I'm no rocket surgeon

View turnkey47's profile

turnkey47

93 posts in 1342 days


#12 posted 09-15-2013 12:11 PM

great looking board!!! great blog!!! thanks for taking the time to show how its done!!!

View mloy365's profile

mloy365

433 posts in 1781 days


#13 posted 09-15-2013 12:15 PM

Wow! what an excellent presentation. And the board is outstanding too!

-- Mike - Northern Upper Michigan

View Tkf's profile

Tkf

37 posts in 578 days


#14 posted 09-15-2013 12:26 PM

Awesome.

View KnotCurser's profile

KnotCurser

1833 posts in 1719 days


#15 posted 09-15-2013 12:36 PM

Fantastic blog!

Thanks for taking the time and effort to document this process

-bob

-- Robert Rhoades WoodWorks / Email: rrww@rhoadesclan.com / www.rhoadesclan.com

showing 1 through 15 of 37 comments

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