Help with Edge Grain Cutting Board - Thickness and Suspension
I could use some advice for the design of an edge grain cutting board.
I would like to build a nice cutting board that will fit across a farmhouse sink and not fall in. The farmhouse sink has a single basin like a small bathtub. The cutting board should be able to slide left and right while fitted across the sink. When pushed against one side or the other, the cutting board should be level with the granite counter. The granite counter partially covers the top edge of the sink on three sides.
The cutting board will be 12 inches wide by 18 inches deep. The granite counter is 2 centimeters above the top of the sink. The sink is approximately 30 x 18 inches.
The cutting board should be flat and stable when suspended across the sink or if placed on a countertop. Depending on the design, I would make some kind of feet with rubber inserts.
I originally wanted to make a thick, massive cutting board until I realized how much it would weigh. My spouse won't use it if it weighs too much. Now I wonder how thin I can make it (2 cm?) and still be strong and stable.
* How to Suspend the Cutting Board over the Sink?
I thought about trying a cove cut on the table saw for the front and back of the sink, so that the solid cutting board would curve over the front and back edges of the sink. Another option would be to attach thick wood strips to the bottom of the cutting board. They would press against the inside front and inside back of the sink, and could hold the rubber feet on the bottom. (It just occurred to me that I could rabbet the bottom edges as another solution, but it might not look as nice, and a thick cutting board might weigh too much.)
* How to match the curves of the sink edges?
Related to the above. When the cutting board is pressed against the left or right edge of the sink, it must thin to 2 cm on the edges, to accommodate the sink/counter interface.
* How to match the wide flat corner curves of the counter?
How do I copy the wide corner curves of the counter, so that the cutting board corners fit perfectly.
* Can I get by with my existing tools? ... or does it make sense to buy something?
I have a great table saw with a superb Forrest blade. I like to think that it cuts nearly as clean as a jointed edge. I also have a nice 8 inch dado set.
I do not have a bandsaw, jointer, planer or router table. I have a very sucky, 1970s Craftsman 1-speed handheld saber saw. It is hard to control. I have an old, cheap 1970s Craftsman drill press with various bits including hole saws, sanding cylinders, specialty bits like spades, Forstners, etc.
I have an old 1980s Black and Decker 1.25 horsepower fixed base router with a 1/4 inch chuck. I have the usual hand tools, including a few basic chisels, hand planes (which I am not yet skilled at using), and handsaws.
I do not mind buying the right tools, bits, or jigs (or making them) if it makes sense, but I try to make do with what I already have. I will trade time and labor to save on tools, but I don't want to compromise on quality. If it's time to buy a tool, then it can happen.
HERE ARE MY QUESTIONS:
1. How thick (or thin) should I make a 12 x 18 edge grain cutting board that is strong enough to suspend itself by the long ends, and still hold a 40 pound turkey for carving? Remember, the cutting board can't weigh too much, or my spouse can't lift it and won't use it.
(Should I change plans and go with a side-grain cutting board instead? Would it be stronger?)
2. How would you suspend the cutting board over the sink so that the flat top aligns with the granite counter, and the cutting board won't fall into the sink?
3. How would you accommodate the left and right side of the sink, so that the sink won't block the cutting board from reaching the left or right edge of the counter?
4. How would you copy the flat curve of the counter corners and match them on the cutting board's corners?
5. I am a novice woodworker. Am I asking the right questions? Have I made some invalid assumptions?
What would you change to help me build a very special cutting board for my spouse?
Thanks in advance to all who respond!
Last edited by Tool Agnostic; 10-30-2017 at 06:48 PM.