Looking to create something special from a simple piece of wood? Syd from Syd’s Workshop has crafted an amazing project that transforms an ordinary 2×4 into 24 stunning coasters. This guide will walk you through the steps.
Materials and Tools Needed
- 1 piece of 8-foot 2×4
- Table saw
- Planer
- Router
- Sanding paper (220 and 320 grit)
- Polyurethane finish
- Car polish and wax (optional)
- Cardboard cylinders (for drying)
- Microfiber cloth
- Paper towels
Step 1: Selecting the Wood
Syd found a beautiful piece of wood at the bottom of a bundle of 2x4s at Lowe’s. The unique color of the wood, which develops after a tree dies and the sap flows down, was an inspiration for this project. After purchasing the 2×4, Syd waited two months before deciding to turn it into coasters.
Step 2: Cutting the Coasters
The target size for each coaster is 3.5 inches by 3.5 inches. With an 8-foot 2×4, Syd calculated that cutting the board into 16-inch lengths would yield 4 coasters per piece. However, during the initial attempt to cut the wood in half, things didn’t go as planned.
Experiencing kickback on the table saw, Syd quickly adjusted the approach by using a planer to flatten each piece of wood instead. Once the pieces were ready, the table saw was brought back out to cut them to their final size.
Step 3: Rounding the Edges
To soften the sharp edges of the coasters, Syd used a router. Starting with a 1/8 inch roundover bit, he quickly upgraded to a 1/4 inch bit for a smoother finish. A makeshift router table was created by flipping the router upside down, allowing for more control.
Despite some battery issues with the router, the next morning Syd finished the edges of the coasters with the desired roundover.
Step 4: Sanding the Coasters
Each coaster was sanded using 220 grit followed by 320 grit sandpaper. This preparation was crucial for applying the polyurethane finish later on.
To allow for even drying, Syd used cardboard cylinders to prop up the coasters while applying the first coat of polyurethane. He carefully coated the sides, then held the coasters by the corners to finish the top and bottom.
Step 5: Applying the Polyurethane Finish
After letting the first coat dry, Syd sanded the coasters again to remove any imperfections. He noticed a small ring left by the cardboard but quickly fixed it by sanding in the direction of the grain.
Once the second coat was applied, the coasters were brought back in for their final finish. The time-consuming process paid off, resulting in a beautiful, smooth surface.
Step 6: Wet Sanding and Polishing
For the final touch, Syd decided to wet sand the coasters using three different grits of sandpaper (600, 1200, and 2000). This step enhanced the smoothness and shine of the coasters.
After wet sanding, a two-part car polish was applied, followed by a coat of car wax for added protection. This ensures that the coasters are not just beautiful but also functional and waterproof.
Step 7: Testing the Coasters
As a parting gift for a friend, these coasters were put to the test. They successfully held both a cold beverage and a glass of iced water without sticking, proving their effectiveness.
Conclusion
Transforming a simple 2×4 into beautiful coasters is not only a rewarding woodworking project but also a fantastic way to practice your skills. With patience and creativity, anyone can create functional art for their home or as gifts. So grab your tools and get started on your own set of stunning coasters!