This project is by BYOT. This DIY project is not only budget-friendly but also allows you to add a personal touch to your home decor.
Step 1: Gather Your Materials
To make these coasters, you will need:
- Scrap Plywood
- Titebond 2 (wood glue)
- Sand Paper
- Walrus Oil (furniture finish)
- Rubber or Felt Feet
Make sure to have the right tools handy, including a table saw, chop saw, and sander.
Step 2: Cut the Plywood
Start by cutting a manageable chunk of your scrap plywood. For this project, we are using apple ply, which is thick, dense, and straight.
Step 3: Sand the Edges
Once you have your pieces cut to approximately half an inch thick, sand down any rough edges using an oscillating spindle sander or a standard sander.
Step 4: Set Up for Precise Cuts
Next, create a stop block on your chop saw to ensure all cuts are the same size. This will speed up the process and maintain precision.
Step 5: Cut Different Styles
Now, cut your plywood into two styles of coasters: square and mitered edge. Adjust the angle of your chop saw to 45 degrees for the mitered edges.
Step 6: Start Gluing
Prepare your workspace with plastic wrap to protect surfaces. Use Titebond 2 for gluing the pieces together, applying glue to one side and pressing them together.
Step 7: Align and Secure
Align the pieces carefully to minimize gaps. You may not need clamps, but ensure you have a secondary rail for support.
Step 8: Let the Glue Dry
Allow the glued pieces to dry for about 24 hours. Once dry, use a putty knife to gently release them from the form.
Step 9: Sand the Coasters
Now it’s time to sand the coasters using a Bosch sander with 60 grit sandpaper to remove excess glue and ensure a flat surface.
Step 10: Shape the Coasters
Using a level and clamps, mark a line for cutting any excess material. Cut with a circular saw for a clean edge.
Step 11: Finalize the Size
Use the chop saw and stop block to cut each coaster to its final size. You can create different sizes for variety.
Step 12: Add Character with Routing
Use a router with a round over bit to smooth the edges and give your coasters a professional finish.
Step 13: Finish Sanding
Hand sand each piece with 200 grit sandpaper for a smooth finish. Make sure to sand all edges and surfaces.
Step 14: Branding the Coasters
For a personal touch, use a custom branding iron to add your mark to the coasters.
Step 15: Apply the Finish
Dip the coasters in Walrus Oil for a beautiful finish. Let them soak and dry overnight for durability.
Step 16: Attach Feet
Finally, add rubber or felt feet to protect your surfaces and enhance the coasters’ stability.
Step 17: Enjoy Your Coasters!
You now have beautiful coasters made from scrap wood! They make great gifts and add a personal touch to your home.
