This project was built and designed by David from dk builds. It’s a highly efficient batch woodworking project that results in over 100 unique coasters made from a variety of beautiful hardwoods.
Designed with both gifting and selling in mind, these coasters—coined “hectocoasters” by David—demonstrate how smart material choices and repeatable processes can turn a pile of lumber into a profitable product line. The project also provides a great way to practice joinery, layout, and finishing on a small, manageable scale.
Watch the full video and subscribe to David’s channel:
Choosing the Right Materials
David sourced both domestic and exotic hardwoods to bring variety and visual appeal to the project. Walnut, oak, and maple formed the base of the designs, while colorful woods like mahogany, purple heart, and padauk were used as accent strips.
The total cost of the materials came in around $100. For a batch of over 100 coasters, that makes each unit cost less than a dollar in materials—an impressive baseline for potential profit.
Milling and Preparation
The first step was to joint one face and one edge of each board. This established a square reference surface, making the following cuts more accurate and consistent.
Once jointed, the boards were cut down to manageable lengths, typically long enough to allow several coasters to be cut from each one. This step was done efficiently to reduce waste and prepare for layout.
Visual Layout and Design Variations
Before glue-up, David arranged the boards in different combinations to test out various design patterns. Playing with color and grain direction created 18 unique sets of boards, each yielding six coasters.
By resawing and cutting these down after glue-up, he was able to scale the process and still keep each set visually distinct. This made the final batch feel more like a curated collection than a single repeated design.
Glue-Up in Batches
With so many pieces in play, batching became critical. David applied glue strategically, aiming for a light squeeze-out to avoid mess and cleanup.
Each glue-up was clamped using five clamps to ensure even pressure. Working in batches allowed him to maintain consistency without being overwhelmed, and he was able to keep a steady rhythm throughout the day.
Resawing with Precision
Instead of using a bandsaw, David used his table saw for resawing. Multiple passes with a thin kerf blade helped keep the cuts controlled and square.
After resawing, the boards were planed lightly to remove any saw marks and bring them to final thickness. This combination of table saw and planer kept the boards flat and made the next steps much easier.
Final Shaping and Edge Work
Each board was chopped into coaster-sized sections, typically thirds, to get six coasters per layout. Once cut, the edges were rounded over using a router—particularly important on the end grain to prevent chipping.
A light sanding focused on the edges and top face. The bottom was left rough, as it would be covered by cork in a later step.
Finishing for Durability
For finish, David used General Finishes Armor Seal, a durable topcoat well-suited for high-use items like coasters. He applied several thin coats, sanding lightly between them to achieve a smooth, water-resistant surface.
This finishing method not only protects the wood but also enhances the contrast between the different species, making each coaster stand out visually.
Adding the Cork Base
Once the finish had dried, David cut cork squares to size and adhered them to the bottom of each coaster. He used spray adhesive, which proved quicker and cleaner than traditional wood glue.
To seal the cork and wood together, a final thin coat of finish was applied. This gave each coaster a unified look and ensured everything was locked in place for daily use.
Why Hectocoasters Work
The hectocoaster is a perfect example of how small projects can be scaled for volume. Whether you’re gifting them, selling them at markets, or listing them online, the coasters strike a great balance between craftsmanship and efficiency.
By using scrap wood or inexpensive offcuts, this project maximizes yield while keeping costs low. And because of their small size, they’re easy to ship, store, and customize.
A Great Project for Every Woodworker
Whether you’re looking to practice batch woodworking or create a market-ready product, this project offers plenty of value. From material selection and glue-up strategy to efficient finishing, each step is designed with repeatability in mind.
Hectocoasters are quick to make, fun to design, and appealing to just about anyone who enjoys handmade goods. They also make excellent entry-level items for selling your woodworking online or at local events.
Please support David by visiting his Etsy Store and buying his plans.