Looking to create a beautiful and functional serving tray? Bruce A. Ulrich has crafted a stunning spalted white oak serving tray featuring gentle, sloping curves and live edges. In this guide, Bruce walks through each step of the process, ensuring that anyone can recreate this elegant piece.
Materials and Tools Needed:
- Spalted white oak
- Wood glue
- Wood screws
- Dowels
- Mahoney’s walnut oil
- Wax paper (for glue application)
- Center punch
- Table saw
- DeWalt planer
- Supermax drum sander
- Trim router
- Random orbit sander
- Drill & driver
- Miter saw
- Jointer
- Chisel
- Hammer
- Flush trim saw
Step 1: Prepare the Wood
Bruce starts by measuring the lengths needed for the tray. Using a miter saw, he crosscuts the wood to rough dimensions. Next, he takes the pieces to the jointer to ensure one flat face, followed by the planer to make the opposite side flat and parallel.
Step 2: Create the Panel
After prepping the wood, Bruce rips down the side strips and the panel pieces on the table saw. Once the panel is glued together, he removes it from the clamps, using wax paper to prevent glue from sticking to the clamps. He then trims the panel down to size using a crosscut sled on the table saw.
Step 3: Design the End Caps
Bruce visualizes the end caps for the tray and decides on a sloping curve. Using a set of French curves, he marks the high and low points before cutting them out on the bandsaw. The result is a visually appealing design that complements the tray.
Step 4: Create Inset Handles
Next, Bruce marks a series of holes for the inset handles and drills them on the drill press. He cleans up the holes with a chisel and some file work for a polished finish.
Step 5: Lay Out for Screws
Bruce meticulously lays out the lines for the screws, ensuring precision in their placement. This attention to detail makes a significant difference in the overall appearance of the tray.
Step 6: Sanding
After assembling the tray, it’s time for sanding. Bruce uses a random orbit sander for most areas and an angle grinder with a flat disc for the live edges to remove any splinters.
Step 7: Roundover Edges
Using an eighth-inch roundover bit, Bruce rounds all the edges that will be touched by hands, ensuring a smooth feel.
Step 8: Assemble the Tray
Bruce attaches all components using screws, countersinking them to allow for dowels that will plug the holes later. He faces a challenge when the dowel plugs are too large, leading him to adjust his approach using smaller pieces.
Step 9: Trim and Sand Dowels
After hammering the dowels into place, Bruce uses a flush trim saw to cut off the excess. He then sands the area to ensure everything is flush.
Step 10: Final Sanding and Finish
Bruce completes the finishing touches with hand sanding up to 220 grit before applying Mahoney’s walnut oil. He generously wipes it on, allows it to sit, and then wipes off the excess for a beautiful finish.
Conclusion
This project is not only fun but also results in a stunning piece that showcases the beauty of spalted wood. Bruce reflects on the process and encourages viewers to subscribe for more woodworking projects. The unique spalting in the wood is highlighted beautifully by the finish, making it a gift that the recipient is sure to cherish.
