This project was built and designed by Billy from Newton Makes. It focuses on designing a project as you go—an intuitive, flexible approach that helps woodworkers create beautiful results without being locked into a rigid plan.
Billy demonstrates this technique through the build of a custom wooden tray, showing how spontaneous decisions, guided by the wood itself, can shape the final design. It’s an ideal method for those who feel overwhelmed by having to plan every last detail before even making the first cut.
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Starting with What You Have
Instead of beginning with a detailed diagram or cut list, Billy lets the materials lead the way. In this case, he starts with four-quarter walnut and maple—two hardwoods known for their durability and visual contrast.
By cutting the boards into strips, he creates pieces that can be laminated into a thicker base. This method allows for layout flexibility and opens the door to creative striping patterns that emerge during the build.
The contrast between walnut and maple is used to form an alternating visual effect. It’s not a look that was pre-planned—it evolved naturally as Billy evaluated the layout strip by strip.
Embracing On-the-Fly Design
Rather than sketching every detail beforehand, Billy makes decisions step by step. He experiments with where to place lighter or darker pieces and considers small layout changes as the visual balance develops.
This spontaneous approach removes pressure and keeps the project fun. It also allows the final look to be shaped by the material’s grain patterns, color differences, and personal preference as the piece takes form.
Gluing and Milling the Blank
Once the strips are finalized, the next step is gluing everything together. Billy uses lightweight clamps to hold the tray blank tight while the glue sets. It’s important that the boards stay flat and aligned, so good clamping pressure is key.
After the glue dries, the blank is milled flat. This includes both planing and jointing to ensure smooth surfaces and a consistent thickness throughout the piece before routing begins.
Creating the Tray Recess
To shape the inner cavity of the tray, Billy uses a router paired with a shop-made MDF template. This ensures the trench is centered and uniform.
Before routing, excess waste is removed with a drill press to reduce the load on the router bit. This step improves both safety and efficiency, minimizing tear-out and giving the router a clean pass.
The trench is then cut using a bowl router bit with a bearing that follows the edges of the MDF template. A supporting jig keeps the workpiece secure during the cut, providing additional safety and control.
Building and Shaping the Handles
Handles are added on each end to make the tray easy to carry. Billy mirrors the curve of the routed trench for visual consistency, marking out a flowing shape that feels natural in the hand.
Material is removed using a jigsaw and refined at the router table for smooth curves and soft edges. Sanding continues the refinement process, ensuring each handle is as pleasant to hold as it is to look at.
Sanding and Applying the Finish
Before applying a finish, Billy gives the entire tray a careful sanding, progressing through multiple grits. This ensures a surface free of glue residue, tool marks, and rough grain.
For the finish, Billy applies a hard wax oil. This type of finish penetrates the wood and enhances the grain without creating a plastic-like topcoat. It’s rubbed in thoroughly, allowed to dry, then given one or more follow-up coats for added depth and protection.
The end result is a finish that feels natural to the touch and looks great from every angle. It also provides water resistance, making the tray practical for daily use.
Why Spontaneous Design Works
One of the main lessons from this project is that woodworking doesn’t always require a complete blueprint. Billy’s approach emphasizes flexibility, creativity, and responsiveness to the material.
Instead of worrying about getting every detail right before starting, this method encourages woodworkers to engage with the process. You get to adapt based on what looks and feels right as the project unfolds.
A Tray That Reflects the Process
The final tray is functional, attractive, and unique. It’s also a reminder that great design can emerge naturally when you’re willing to let go of control and let the work evolve.
This tray may have started as a rough idea, but through smart decisions and hands-on shaping, it became a polished, heirloom-quality piece. Billy’s technique is an excellent tool for woodworkers who want to build with more freedom and less stress.
Please support Billy by visiting his website here: https://www.newtonmakes.com/shop.