This plywood desktop was created by Penalty Box Woodshop, and it’s perfect for any home office setup.
Materials Needed:
- 3/4″ plywood (1/2 sheet)
- Formica laminate (4×8 sheet)
- Walnut for edge banding
- Titebond wood glue
- Contact cement
Tools Required:
- Track saw or circular saw
- Biscuit joiner
- Router with flush trim and round over bits
- Sander (orbital or hand)
- Clamps
- Foam roller
Step 1: Prepare the Plywood
Start by cutting the plywood to the desired length and width for your desktop.
Step 2: Create Edge Banding
Next, cut the walnut to the same width as the plywood. This will serve as edge banding, giving your desktop a refined look. Use pipe clamps to hold the pieces in place while you mark where to cut for biscuits.
Step 3: Cut Biscuit Slots
Using a biscuit joiner, cut slots in the plywood and the walnut pieces. This will help align the boards during glue-up.
Step 4: Glue the Edge Banding
Apply Titebond wood glue to the walnut and insert the biscuits. Attach the walnut edge banding to the plywood, ensuring to use enough clamps to hold everything in place while it dries.
Step 5: Sand the Surface
Once the glue has dried, remove the clamps and sand the entire surface of the desktop with 80 and 100 grit sandpaper to ensure a smooth finish for the laminate application.
Step 6: Cut the Laminate
Open your Formica laminate and cut it about four inches longer and wider than the tabletop. This will ensure you have enough overhang when gluing it down.
Step 7: Apply Contact Cement
Apply contact cement to both the laminate and the plywood surface. Let it dry until it is tacky before bringing the two surfaces together.
Step 8: Attach the Laminate
Carefully align and lay down the laminate onto the plywood, rolling it out to avoid air bubbles. Use weights to hold it down while the cement cures.
Step 9: Trim the Laminate
After the cement has cured, use a router with a flush trim bit to trim the laminate flush with the edges of the plywood.
Step 10: Finish the Walnut
Sand the walnut edges to a smooth finish and apply Rubio Monocoat Pure for a beautiful, durable finish.
Final Thoughts
And there you have it! A simple yet elegant plywood desktop that looks great in any home office. This project was not only easy to complete but also made use of materials already had on hand.