This project was built and designed by Sam Macy. It’s a series of handcrafted charcuterie boards made from black walnut and maple, featuring custom epoxy inlays for added visual appeal.
Sam walks through the process of turning rough boards into elegant serving pieces, combining traditional shaping techniques with modern resin work. These boards make excellent gifts and are ideal for anyone looking to create custom woodworking products with a high-end look.
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Starting with Quality Materials
For this project, Sam uses black walnut and maple, two hardwoods that contrast beautifully when finished. A piece of live edge wood is also incorporated to give some of the boards a more organic, rustic feel.
The plan is to create a batch of roughly eight boards in one go, making the process more efficient and repeatable. This approach allows for experimentation with different shapes, finishes, and epoxy designs while streamlining setup and workflow.
Preparing and Shaping the Boards
After selecting the lumber, the boards are cut to manageable sizes using a track saw or table saw. Sam then uses a template and router to shape the boards into consistent, pleasing forms.
One standout technique involves using a double-bevel sanding disc. This tool creates a chamfered edge around the boards, softening the look and improving hand feel. It’s a detail that adds to the overall craftsmanship and professionalism of the final product.
Planning and Pouring the Epoxy Inlay
With the boards shaped and sanded, the next step is creating the epoxy inlays. These designs are based on custom line drawings, which are routed into the board surface before being filled with resin.
The epoxy is mixed carefully and tinted with pigment to create contrast against the walnut background. Once mixed, it’s poured into the engraved sections and leveled with care to avoid overfilling or creating bubbles.
This part of the process takes time and precision. Allowing the epoxy to fully cure is critical to ensure clarity and durability. Sam emphasizes the importance of not rushing—patience results in cleaner, sharper inlays and fewer imperfections during final sanding.
Refining the Surface
After the epoxy has cured, the boards are sanded again—this time starting with a coarse grit and working up to 320 grit. The goal is to remove any excess epoxy while leaving a silky-smooth finish on the board’s surface.
During this stage, Sam carefully rounds over the edges and checks for any small defects or dips. This quality control step ensures every board has a consistent look and feel, even across multiple variations.
Applying a Food-Safe Finish
The finishing process starts with a quick wipe-down to remove dust, followed by an application of Rubio Monocoat. This oil-based finish is food-safe and enhances the natural grain of both the walnut and the inlaid resin areas.
Rubio Monocoat is applied in thin layers and allowed to cure, creating a protective seal that keeps the board safe for food contact. The finish also adds depth and warmth to the wood, highlighting its natural tones.
Reflections and Opportunities for Improvement
While the boards turned out great, Sam notes that future versions might benefit from trying a different epoxy formulation. Some small bubbles appeared during curing, which could be avoided with a slower-setting resin or vacuum chamber.
This feedback loop—reflecting on the process and looking for improvements—is a key part of woodworking. Each build is a chance to learn something new, especially when working with materials like epoxy that require extra attention.
A Project That Combines Creativity and Skill
Charcuterie boards are a perfect woodworking project for all skill levels. They’re compact, easy to batch, and offer endless customization opportunities through shape, species, and decorative elements like inlays.
Sam’s process shows how combining traditional wood shaping with creative resin work can elevate a basic serving board into something unique. It’s also a great way to experiment with new tools and materials on a small scale.
Whether you’re looking to build a set of gifts, sell your work at local markets, or simply create something beautiful for your kitchen, this project offers both challenge and reward.
Please support Sam by visiting his website here: https://sammacydesigns.com/.