This project was built and designed by Nick Starrett from Nick’s Custom Woodworks. It’s a great example of how leftover materials can be turned into something both practical and attractive for the shop.
If you’ve been saving scrap hardwood from previous builds, this is a creative way to put those pieces to use. Nick used years’ worth of Ash offcuts to construct a full butcher block-style countertop for his new workstation.
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Getting Started with the Scraps
Ash is a dense, durable hardwood, making it ideal for a butcher block surface. But working with scraps requires extra prep to ensure each piece is usable.
Nick began by milling down the rough-cut Ash pieces. Planing and jointing each board helped create clean, flat surfaces for a tight glue-up later.
This step took some time but made the rest of the project much easier. Consistency in thickness is key for a smooth countertop surface.
Gluing the Countertop
With the boards prepped, it was time to glue them into panels. Nick used his own product, Boss Dog Wood Glue, which he recommends for strength and reliability.
The glue was spread evenly across the edges before clamping the panels together overnight. A solid glue-up ensures the butcher block will last through heavy use.
Clamping pressure was applied across the length to keep everything tight and flat. Once dry, the block was ready for sanding.
Sanding and Surface Prep
Nick used a drum sander to quickly remove any uneven spots and bring the surface flush. This sped up the process compared to using only hand tools.
However, he still followed up with a random orbital sander to get a perfectly smooth finish. Starting with 120 grit helped level the surface while keeping the grain intact.
Once the initial sanding was complete, he used a router to round over the edges. This gave the piece a finished appearance and made the edges more comfortable to work around.
Final Sanding and Surface Cleanup
Before the final sanding pass, Nick wiped the surface with a damp cloth to raise the grain. This step helps achieve a smoother final finish by sanding down any raised fibers.
He then followed up with 220 grit sandpaper to refine the surface. The butcher block was now smooth, clean, and ready for finishing.
Applying the Finish
To finish the butcher block, Nick used Austin’s Wood Butter, which enhances the wood’s natural look without adding shine. It also creates a sealed, protected surface that stands up to glue, tools, and daily use.
This type of finish is ideal for shop furniture because it’s easy to apply and maintain. It also brings out the grain in Ash beautifully, giving the countertop a rich, natural tone.
A Smart Use of Scraps
Turning leftover hardwood into a countertop is not only resourceful but also rewarding. Nick’s finished piece adds function to his shop and clears space that would have otherwise gone unused.
A butcher block surface like this is perfect for glue-ups, sanding, or general workbench tasks. It also adds a polished, custom touch to any workspace.
Watch the Full Build:
Please support Nick by visiting his website here: https://www.nickscustomwoodworks.com/.