How I made my Intersected cutting board

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Blog entry by GaryK posted 02-18-2011 08:54 AM 19448 reads 68 times favorited 35 comments Add to Favorites Watch

Here is how I made my Intersected cutting board posted here.

Click for details

There seems to be a lot of interest in this board so here is a blog on how I made it.

First of all here’s what I planned on making. It’s the top one.

After I got both the circles intersected I liked how it looked with the rounded corners so I just added in the “wedge shapes”at the top and bottom and called it done.

I think that it makes it very distinctive also.

As one person guessed I had to make 3 bulls-eyes not two. The third one has the colors reversed with the dark ring on the outside. This was just to get 3 ring segments and the rest was scrap.

The first thing I did was to glue up a bunch of 3/4” stock to give me a total thickness of 1 1/2”.

Then I cut them up on the table saw at 22.5 deg for the 8 segment ring blanks and 45 deg for the 4 segment blanks. The 4 segment pieces are for the 3 smallest rings.

I used these jigs:

Here you can see me working on the largest rings

You can see in the front is the maple ring all setup for the router table. I turn the inside first using the previous rings as a gauge. To give myself a pivot point I nailed a piece of hardboard to the ring. I nailed close to the point so that it would be turned off when the diameter was turned. (after removing the nails) You can see to the left some of the used pivots for the smaller rings.

Here are the jigs I used to create the rings:

Here I turned the inside:

And here’s the outside. Note the arrows to remind me which way to feed it.

Now with the bulls-eyes complete comes the part of intersecting them. For that I need another jig:

This one the cuts the arc from the bulls-eye and for cutting the smaller piece that fill fit into it. This jig was placed on top of the jig used to cut the outer part of the rings.

Here you can see that I removed a section for the dark ring. The big piece on the left is waste. The 2 pieces to the right have already been turned on the outside.

Here you can see the light ring with the dark segment before gluing.

Here they are glued up and in the jig ready to cut the arc to size. The bar across the top was to keep the bullseye from spinning as I cut it.

Cut glue cut glue…

Here you can see the jigs I used. To the left are the waste parts. In the middle you can see the jig after I was done with it. Not much left of it. The round jig was the cut the two wedges for the top and bottom. There are two pivot points and again a clamp to hold the part down.

For all the pivot points I used 1/4” dowels.

Now you must be wondering about the smallest circle in the middle. The bulls-eye? Well, after I was done with everything else, I plugged the pivot hole and drilled a 1” hole through the middle and plugged it with a piece of maple to complete it.

A couple of times through the drum sander and then the RO sander and I’m done. Mineral oil for the finish and it’s ready for the knife!

I’ll try to answer any questions if you have any.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

35 comments so far

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 3867 days

#1 posted 02-18-2011 09:17 AM

Gary, that is some bit of thinking.
Great board.


-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View TopamaxSurvivor's profile


20269 posts in 4686 days

#2 posted 02-18-2011 09:26 AM

Thanks for clearing it up;-)) I thought all you used wasa bandsaw. Either way, awesome piece of work!!

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View degoose's profile


7281 posts in 4365 days

#3 posted 02-18-2011 11:14 AM

Need I say any more but …SLICK…..

-- Don't drink and use power tools @

View BigTiny's profile


1687 posts in 3899 days

#4 posted 02-18-2011 12:37 PM

Thank you for sharing. Well thought out method and great workmanship. I’ll have to try one of these.

-- The nicer the nice, the higher the price!

View Mike Gadsby's profile

Mike Gadsby

37 posts in 3996 days

#5 posted 02-18-2011 01:15 PM

I see you live in East Texas you wouldn’t by chance be a ROCKET SCIENTEST at NASA during the day would you?Pretty ingenuis how you come up with that.Amazing!

View herg1's profile


42 posts in 4723 days

#6 posted 02-18-2011 02:27 PM

Gary that is a great piece of work and thanks for sharing it with all of us. We are not too far from each other, I’m in Waxahacie, I’d like to stop by and visit one of these weekends if you have no objection.

-- Roger1

View Lee A. Jesberger's profile

Lee A. Jesberger

6873 posts in 4990 days

#7 posted 02-18-2011 02:59 PM

Hi Gary;

Always the genius…Very nicely done.

The construction details and workmanship are impressive, to say the least.


-- by Lee A. Jesberger

View mot's profile


4928 posts in 5047 days

#8 posted 02-18-2011 03:50 PM

Mind boggling, Gary. I continue to be amazed, and admittedly overwhelmed, by the detail of your work. Even a cutting board becomes a complex symphony of precision. Thank you for taking the time to blog it!



-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View Dennisgrosen's profile


10880 posts in 4126 days

#9 posted 02-18-2011 04:04 PM

thankĀ“s for taking the time to make the blog … day I might understand it ….. :-O

take care

View CharlieM1958's profile


16292 posts in 5229 days

#10 posted 02-18-2011 04:43 PM

Brilliant thinking, Gary. I have one comment, though:

-- Charlie M. "Woodworking - patience = firewood"

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 4297 days

#11 posted 02-18-2011 04:43 PM

Now my brain hurts.

Thanks for the blog—-Great information and awesome design


View bigike's profile


4057 posts in 4299 days

#12 posted 02-18-2011 04:54 PM

Thanks for the posting this info.

-- Ike, Big Daddies Woodshop, http://[email protected]

View GaryD's profile


623 posts in 4380 days

#13 posted 02-18-2011 05:36 PM

Gary, thanks for the post, I will be truying this myself. Does your brain still hurt from figuring this out?

-- Gary, Little River,SC I've Learned that the Lord didn't do it all in one day and neither can I

View Blake's profile


3443 posts in 4885 days

#14 posted 02-18-2011 06:03 PM

Way cool

-- Happy woodworking!

View a1Jim's profile


118161 posts in 4588 days

#15 posted 02-18-2011 06:50 PM

Thanks Gary you always come up with innovative projects and techniques great blog


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