The Process of Making These Boards
From wood selection to finished product involves 7 to 8 steps or processes.
Each simple board takes 4-6 hours in total, spread over about 7 days.
More unusual boards with inlays or similar features can take an additional 4 or even 6 hours.
I only make a couple of patterns at a time as wood selection takes time.
Selection : For each board I select a main piece, then build the pattern around that using pieces from my wood collection.
Dimensioning and gluing: Each individual wood piece once selected, is cut to the approximate required dimensions, then fitted into the design and glued up using either waterproof wood glue or resin glue where resin is included. Gluing requires multiple clamps.
Rough dressing : Each roughly glued board is then dressed to flat and square. Flattening can be by a planer or sanding with 45grit.
Sanding and blemish repair: The next process is to rough sand the board. Sanding involves multiple passes each removing scratch marks from the coarser grit that proceeds it. I start with 45grit, then 60, 80, 120 and 150grit. Any cracks / splits/ holes are repaired at this stage.
Edging and recessed handles : Next the edges are rounded with a router and if there are handle recesses these are also cut in with a router.
Resin or timber inlays : Any special resin insert requires that the board is again cut, then reglued with the insert included and the above process largely repeated.
Finishing sanding : Each piece is finish sanded starting with 150 grit, then 180, 240 then a thorough clean and 320 grit and another clean.
Finishing : 3 or 4 coats of food safe hard wax oil, a 500grit sand and finally food grade wax and polish.
