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A few months ago, a furniture builder in Toronto gifted an impressive collection of walnut scraps, sparking inspiration for a woodworker’s latest project. After using 116 pieces to create a unique coffee table, the remaining walnut pieces sat idle—until an idea struck. Inspired by feedback on the coffee table, particularly the end grain’s visible charm, the woodworker realized these scraps were perfect for crafting a large end grain cutting board. This blog post details the meticulous process, lessons learned, and the journey of bringing this project to life, resulting in a high-quality cutting board ready to sell.
Key Takeaways
- Walnut scraps can be repurposed for unique woodworking projects like end grain cutting boards.
- Precision is key: A single mistake could result in the entire project being scaled down.
- Woodworkers should let glue cure fully and avoid rushing—patience saves time in the long run.
- Router sleds are a game changer for flattening large boards that won’t fit through a planer.
- Quality takes time: This project totaled about 5 hours and 25 minutes, with careful attention to detail from start to finish.
The Creation Process
Armed with 42 remaining walnut pieces, the first step was to trim each piece into squares, forming the foundation of the cutting board. Once assembled into 5-piece glue-ups, it became clear that not all pieces aligned perfectly, resulting in gaps. Using a jointing jig, the woodworker flattened the faces, ensuring a flawless fit between segments. After regluing the sections that broke during the process (due to insufficient curing time), the cutting board began taking shape.
The Power of the Router Sled
Since the board was too large for a planer, the woodworker turned to a new tool—a massive router sled designed to flatten oversized boards. By carefully securing the board with hot glue and using a large carbide-tipped bit, one side was flattened with precision. This tool proved to be a time-saver, significantly reducing the need for extensive sanding later in the project.
Final Touches and Ready for Sale
After flattening both sides, the board was sanded to perfection, rounding the edges with a quarter-inch roundover for a refined finish. Branding was added to the back of the board, followed by the application of a homemade mineral oil and beeswax finish. With the addition of non-skid feet, the cutting board was complete and ready for sale. After some careful pricing calculations, the cutting board was listed for $325 CAD (or $240 USD).
Although the sale took longer than expected, the woodworker successfully sold the board to a buyer in Singapore, showcasing the power of social media and global connectivity.
Patience, careful planning, and attention to detail paid off in the end. This walnut end grain cutting board exemplifies how scraps can be turned into something functional and beautiful with the right tools and mindset. If there’s one lesson to take away from this project, it’s that taking the time to do things right is always worth it in the end.