From Rough Cut Walnut to a Cutting Block - Woodworking Talk - Woodworkers Forum
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post #1 of 4 Old 11-14-2018, 11:05 PM Thread Starter
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Post From Rough Cut Walnut to a Cutting Block

Hey all -

I have a 8/4 x 8" x 9' walnut board (see attached image).

Moisture content is ~ 5% according to the reader that was having a hard time getting into that walnut.

I'd like to get around a 24x20 end-grain cutting block out of it, as a Christmas gift for the wife.

Looking at around 1 1/2" thickness or a bit more depending on my craftsmanship.

I'm thinking this should be the process, but PLEASE step in if I'm off!

For tools, I have an old ShopFox 6" jointer & 13" Ryobi Planer + table saw, chop saw etc.

Step 1: find a drum sander for later ... because, you know. End Grain.

Other steps ...

Cut the board into 3x 30in sections
Square up the lumber (maybe 7 3/4 at that point).
I'm thinking I'll have to use the table saw. Is 30" of 8/4 walnut too much to slide across that small Shop Fox?

Cut it down the middle (~ 3 5/8 on each section)
Joint out any cups, etc.
Rip to 1 3/4" sticks ... 4 per ~7 3/4" wide, 30" section. This may get me to around 21" wide.
Plane the sticks

Now, can I stop here for a day or 3? Or must I move right to glue-up?

Is there a problem if I do stop? Do I need to clamp everything together?

Glue board faces together showing edge grain
drum sand

crosscut the board every ~ 1 3/4"
Flip boards to get end grain boards around to get a grain mixture

Drum sand again

Route and hand sand, mist water spray, sand & oil.

Did I miss anything? Is anything wayyyy off ... like my math? Or thought process?

Thanks for reading!
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post #2 of 4 Old 11-15-2018, 08:12 AM
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Walnut isn't a very good for a cutting board that is used because of the open grain. The wood is a very open grain wood which can hold bacteria.

You have more than enough wood to make the cutting board. It's 374 square inches where you could get 854 square inches out of the board. If it were me I would get a piece of 8/4 maple and mix in into the walnut like a checkerboard. All one species is kind of boring.

Since the wood is rough if you would just send it through your planer taking light cuts it should be sufficient to flatten the wood. Then you could cut some of the wood off in a manageable length with a circular saw and joint the wood on both sides making it the same width from one end to the other. From there cut the pieces to length of the table saw and they would be ready to glue up. A 1/4" is a lot to sand off so I don't think I would make the pieces any longer than 1 5/8". I would make strips to the 20" or 24" size a little long so after it is put together you can cut it to it's finished size. Since the cutting board will be washed glue everything together with an exterior glue such as titebond III.

Your sanding process looks alright. I would recommend sanding to 400 grit.
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post #3 of 4 Old 11-24-2018, 09:02 PM
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Tom, good luck from a fellow new englander. Looking forward to seeing how it comes out.

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post #4 of 4 Old 12-10-2018, 10:28 PM Thread Starter
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Hey All - Thanks for the advice. I'm currently edge-glued and RO sanded at 80grit. I added a little bit of maple for some 'flair' -- thanks to CBdesigner for predicting the future and Steve too!

This board is currently 29.5x18.5x1.63 and it's a bit too big for my current skeleton of a crosscut sled (see last image in set - it's just plywood right now) I think.

I used my circular saw with a guide to clean up the ends of the board, but there was some *slight* tear out (7 1/4 60 tooth diablo) -- so not likely I can use this to do my crosscuts with it.

Thoughts? Thanks!

Last edited by tjohobbies; 12-10-2018 at 10:35 PM.
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