|Project by LeeInAZ||posted 07-31-2012 08:17 PM||2269 views||3 times favorited||2 comments|
I made these two items last fall for a charity auction. The tray was a featured project in the October 2010 issue of Wood Magazine. It was made with two 1/4” thick pieces of hard maple laminated around a single 1/2” piece of walnut. The removable tray is a single piece of walnut. The end grain cutting board is also made from walnut and hard maple. The bread dipping tray was finished with clear shellac, and the cutting board with mineral oil.
To make the removable tray, I used a derivation of a box joint jig. I squared up a piece of scrap wood about 1.5” square and 18” long. I put a 1/4” wide dado stack on my table saw, and set the height to 1/4”, and using my miter gauge, put a narrow dado across the bottom.
I then took a piece of 1/4” square tubing, and set it into this groove, so that a few inches of it stuck out the front. I attached this to my miter gauge, and used another piece of 1/4” tubing to set the gap between the edge of the embedded bar and the saw blade.
Then it was just a matter of using a push stick to hold the piece down as I fed it through and then moved each kerf over onto the bar for the next cut. Then rotated it 90 degrees and repeated. It is important to have the height of the saw blade exactly 1/2 the thickness of the wood. You will end up with a nice grid pattern.
For the rest, I just followed the plan as presented in the book.
-- Lee - Phoenix, AZ