These solid wood serving trays were built and designed by Ryan Day Woodworking, and they’re perfect for any occasion.
Materials Needed:
- 4/4 Cherry and 4/4 Maple
- Titebond 3 Glue
- Satin Osmo Polyx Oil
Tools Required:
- Band Saw
- Planer
- Router with template bit
- Table Saw
- Drill Press
- Crosscut Sled
- Featherboard
- Clamps
- Sanding Block with 120 and 150 grit sandpaper
Step 1: Cutting the Wood
Begin by cutting your cherry and maple wood to length for the sides, ends, and bottoms of the trays. For the first tray, I kept the bottom at 3/4 of an inch thick, but it ended up being too heavy, so I decided to resaw it to a target final thickness of about 3/8 of an inch.
Step 2: Planing the Bottoms
Next, run the bottoms through the planer to remove any band saw marks and achieve that final thickness. This will help ensure a smooth finish for your trays.
Step 3: Jointing the Edges
Using a router table, joint one edge of each piece to create a flat surface. This is crucial for accurate assembly. Make sure to apply pressure on the outfeed side of the bit to avoid bowing.
Step 4: Organizing for Glue Up
With all pieces cut, take a moment to organize them before glue-up. This will help prevent any mix-ups. I had a few stressful moments due to limited clamps and space, but it all worked out in the end.
Step 5: Assembling the Trays
After the glue has dried for a few hours, carefully remove the trays from the clamps. Use a scraper to remove any excess glue and sand the edges with 120 grit sandpaper for a smooth finish.
Step 6: Final Cuts and Adjustments
Now it’s time to cut the sides and ends to their final thickness, typically 3/4 of an inch. This step is essential for ensuring that all pieces fit together snugly.
Step 7: Creating the Handles
Build a plywood template for the handles. Use a drill press to remove most of the material, and then refine the shape at the router table. Soften the edges with a roundover bit for a polished look.
Step 8: Sanding and Finishing
After sanding the trays with 150 grit sandpaper, I applied a satin finish using Osmo Polyx Oil. Make sure to follow the instructions for the best results, applying three to four coats as needed.
Conclusion
And there you have it! With a bit of organization and patience, you can create beautiful solid wood serving trays that are both functional and stylish.