This project was built by Jesse from Penalty Box Woodshop. He created a stylish and durable desktop using plywood, accented with walnut for an elegant touch. If you’re looking for a functional and cost-effective way to upgrade your workspace, be sure to check out his channel for more woodworking projects.
Watch the full video and subscribe to Jesse’s channel: Penalty Box Woodshop.
Choosing Materials for the Build
Jesse designed this desktop using three-quarter-inch plywood as the primary material. This provides a strong and stable surface while keeping costs down. To enhance the aesthetics, he added a laminate veneer that complements the black metal base of his standing desk.
For a contrasting edge, Jesse used walnut strips along the sides of the plywood. This combination of materials creates a refined, modern look while ensuring durability.
Preparing and Cutting the Wood
To begin, Jesse cut the plywood to the appropriate dimensions for the desktop. The walnut strips were also trimmed to match the width of the plywood, making them ideal for edge banding. Keeping the design straightforward, he chose to expose the end grain on the short sides rather than mitering the corners.
Securing the Edge Banding
To attach the walnut edging, Jesse clamped the strips to the sides of the plywood. Using a square, he marked out slots for biscuits, ensuring proper alignment during glue-up. This technique helped create a seamless and sturdy bond between the plywood and walnut.
Once the slots were cut with a biscuit joiner, he applied wood glue and inserted the biscuits before clamping everything together. Having a variety of clamps on hand was crucial to keeping the edges secured while the glue dried.
Sanding and Preparing for Laminate
After the glue had fully set, Jesse removed the clamps and sanded the entire surface. Using progressively finer grits, he smoothed out the plywood and walnut to prepare for laminate application. Achieving a clean, even surface was key to ensuring the laminate adhered properly.
Applying the Laminate
Jesse selected a Formica laminate sheet, cutting it slightly larger than the desktop for a precise fit. To apply it, he coated both the laminate and the plywood surface with contact cement. After allowing the adhesive to dry to the touch, he carefully positioned the laminate, pressing it down with a roller to eliminate air bubbles.
Trimming and Finishing the Edges
Once the laminate was secure, Jesse used a router with a flush trim bit to cut away the excess. This step gave the desktop clean, professional edges. To soften the look, he followed up with a round-over bit, smoothing the transition between the laminate and walnut trim.
Finishing the Walnut Edging
For the final touch, Jesse sanded the walnut trim up to 180 grit, enhancing the natural grain. He applied Rubio Monocoat Pure, a finish that highlights the wood’s warmth while providing long-lasting protection. This simple finishing process added depth and richness to the walnut edging.
The Completed Desktop
The finished desktop is sleek, sturdy, and built to handle daily use. The combination of plywood, walnut, and laminate makes it both stylish and practical. By using high-quality materials and simple construction techniques, Jesse created a piece that blends well with his workspace while offering long-term durability.
Watch Jesse’s video for the complete process and support his website: Penalty Box Woodshop.