Ryan Hawkins presents an engaging tutorial on transforming hardwood into a stunning optical illusion end grain cutting board. In this step-by-step guide, Ryan walks viewers through his meticulous process, showcasing techniques that both novices and seasoned woodworkers can appreciate.
Getting Started
Ryan begins by giving credit to the original designer of the cutting board pattern he uses, highlighting that he purchased the plans a few years ago. His first attempts with softwood helped him refine his technique before moving on to hardwood. After several practice runs, he decided to upscale the design from 13 by 13 inches to 18 by 21 inches, adjusting the cut list accordingly.
Milling the Lumber
Using a 12-inch Bosch miter saw equipped with an 80-tooth Diablo finishing blade, Ryan starts by cutting the lumber into rough lengths. He emphasizes the importance of handling large pieces carefully, as they can have bows or twists that cause binding during cuts. Ryan advises taking it slow and adjusting the cuts as needed.
Flattening the Boards
After cutting the rough lengths, Ryan moves on to flattening the boards. Due to the size of the lumber, he utilizes a planer sled—a DIY jig that turns the planer into a jointer. This method allows him to create a flat face on each board before sending them through the planer for additional flattening.
Squaring the Edges
Once the boards are flattened, Ryan uses a jointer to dress one edge before finishing the milling process on the table saw. He highlights the importance of precision, especially when working with a pattern as intricate as this one. Ryan uses a yellow push block from Micro Jig to safely guide the boards through the saw.
Ripping Strips for Assembly
With the milling complete, Ryan begins ripping strips of wood to create the pattern. Precision is key, so he opts for millimeters for his measurements. This careful approach ensures that all pieces are uniform and fit together seamlessly during assembly.
Assembling the Panels
Ryan assembles two opposing panels, ensuring that the pattern is a color negative of each other. He carefully aligns the strips, using pencil lines for glue-up guidance. The panels are then glued together in two stages to ensure a strong bond.
Final Glue-Up and Cleaning
After allowing the glue to set for 24 hours, Ryan breaks apart the panels and labels them for easy reassembly. He then sends the panels through the planer to achieve a tight seam before performing the final glue-up to create one large panel.
Flattening and Sanding
Using a belt sander, Ryan flattens the panels to prepare for the final shaping. He demonstrates care when sanding to avoid damaging the wood, taking light passes to ensure an even finish. The sanding process continues until the surface is smooth and polished.
Finishing Touches
Once the sanding is complete, Ryan applies food-safe mineral oil to the surface, allowing it to soak in before wiping off the excess. He emphasizes the importance of this step to protect the wood and enhance its appearance. A final coat of beeswax adds a protective layer, ensuring the board is both functional and beautiful.
Installing Feet and Final Waxing
With the board finished, Ryan installs rubber feet using a jig for precision. After flipping the board over, he applies wax to the top, ensuring a smooth and shiny finish that will repel water and enhance durability.
