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Project by childress posted 07-04-2010 07:57 AM 4593 views 3 times favorited 19 comments Add to Favorites Watch

I posted a big project a little over a month ago that after being shipped, the customer called with some bad news. The counter I sent him had broke during shipment. Yeah, seems as though it was dropped or more than likely thrown from a truck. After several weeks waiting for reimbursement, I finally was able to rebuild a new one. You know how when doing something for the first time, you realize at the end of the project how and what you could have done better. Well this is one of those opportunities I had. Not only did I do my glue up a lot better than before, I decided not to flatten this myself, but take it up to Socalwood’s “ranch” and make use of his wide belt sander. see this blog for details about my visit. Thanks again Rob for helping me out and saving me a least a days worth of work. It’s off to the engravers next week and then will be finished and shipped out. Maybe a different courier this time…

Specs are 32 X 51 X 2” End Grain Mahogany with a Maple border. Thanks for looking

-- Childress Woodworks

19 comments so far

View Kindlingmaker's profile


2659 posts in 4493 days

#1 posted 07-04-2010 08:27 AM

That’s one big glue up! ...and Rob is a great guy with lots of talent and great machines and will help fellow woodworkers.

-- Never board, always knotty, lots of growth rings

View degoose's profile


7279 posts in 4321 days

#2 posted 07-04-2010 09:17 AM

Nice to see these super sized boards… inspirational..

-- Don't drink and use power tools @

View FlWoodRat's profile


732 posts in 4875 days

#3 posted 07-04-2010 11:48 AM


Sorry to hear about the transportation damage. I am sure your customers were dissappointed too. Were you able to salvage/repurpose any of the damaged top?

-- I love the smell of sawdust in the morning....

View patron's profile


13716 posts in 4307 days

#4 posted 07-04-2010 12:05 PM

good save there ,
extra work ,
but that’s how it is sometimes .

i worked in a cabinet shop for 2 years ,
with a brand new wide belt sander .
it was a paperweight !
the guy smoked so much dope ,
he never hooked it up ,
or the 24” bandsaw either !

this top looks great .

and rob is one smooth guy .

well done !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Eagle1's profile


2066 posts in 4031 days

#5 posted 07-04-2010 12:25 PM

Great job. I couldn’t imangine the glue up. How long did it take you to make it?

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

View OttoH's profile


891 posts in 3976 days

#6 posted 07-04-2010 01:56 PM

They did do a job on that original piece, just goes to show that no matter how indestructible you make something, someone will find a way to destroy it.

I am glad that you were able to use this as a learning experience and change all of those “I should have’s” from the first piece.

Great looking blocks, are there plans for repairing the first one?

-- I am responsible for how I respond to everything in my life - - Deadwood SD

View Jonathan's profile


2609 posts in 4017 days

#7 posted 07-04-2010 04:24 PM

That’s too bad that it happened that way.

Still, if this one is built better, that’s fantastic.

Looks like it definitely got dropped… hard, since it didn’t break right on the glue joints.

I am wondering what you did differently during construction, compared to the first board, other than using the behemoth belt sander?

I’m sure I’m not the only one that has their fingers crossed that this one makes it there in pristine condition!

What a great build! I’m sure it was frustrating, but also an opportunity to improve upon the design/construction/skill of such a large build.

Glad you made lemonade out of lemons!

-- Jonathan, Denver, CO "Constructive criticism is welcome and valued as it gives me new perspectives and helps me to advance as a woodworker."

View childress's profile


841 posts in 4508 days

#8 posted 07-04-2010 04:41 PM

Thanks everyone

Degoose: it’s an honor to hear you say, “inspirational”, thanks

woodrat and Otto: right now the customer still has the old board but once this is shipped to him, he will send me the broken one to cut down and send back as a smaller “cutting board”.

Eagle1: All boards are about a 3 day process of milling, glue ups and sanding. This one took only one extra day of glue up because I did it in pieces and then glued together as one. still gotta sand it with my ROS though!

Jonathan: I approached the glue up differently. Last time, I did it in smaller chunks and basically had a harder time of flattening it in the end. This time, glued it up in much bigger pieces and flattened it first, then I actually cut this after being sanded into three big sections so I can get it engraved. After engraving, it will glue back together effortlessly….

-- Childress Woodworks

View JJohnston's profile


1622 posts in 4257 days

#9 posted 07-04-2010 04:46 PM

How are you packaging it for shipping?

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

View childress's profile


841 posts in 4508 days

#10 posted 07-04-2010 05:21 PM

I packaged it like any other counter top. Wrapped a box around it. I also wrapped it tight with bubble wrap to prevent dings and scratches. I didn’t think I would have to do it any other way or put any “cautions” on the box because it weighed 70lbs. and thought if anyone picks this up, they wouldn’t be stupid enough to throw it. Or if it was dropped, why was it off the ground to begin with? These are all speculations as to what happened but the courier investigated and asked me no questions, just cut me a check.

-- Childress Woodworks

View Ken90712's profile


17919 posts in 4155 days

#11 posted 07-04-2010 05:22 PM

Great work I don’t know how I missed the first post. I was sorry to here that the shipping company did this to your work of art! Again Very Well Done! Great work indeed, I look fwd to getting down to meet rob and buy some wood from him. Everyone says what a great guy he is. I’ll have to look you up when I’m down in Fallbrook seeing one of my buddies. Hope 2nd shipping goes or went better on you!

-- Ken, "Everyday above ground is a good day!"

View childress's profile


841 posts in 4508 days

#12 posted 07-04-2010 05:27 PM

Thanks Ken, would love to meet you. Fallbrook is very close to me. Right on the way for you, unless you take the 5…

-- Childress Woodworks

View JJohnston's profile


1622 posts in 4257 days

#13 posted 07-04-2010 05:48 PM

It looks to me like it was dropped onto its corner. As for being off the ground, it has to be handled by hand at some point in its trip.

The reason I ask is because end-grain pieces like this are inherently weak in bending (particularly when they’re big), and cardboard and bubble wrap don’t offer any bending reinforcement. You might consider building a shallow crate out of 2 sheets of plywood with a lumber frame surrounding the countertop and bubble wrap, instead of cardboard. This would probably double the shipping weight, but it would improve your chances of surviving the “gorilla test”.

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

View Dark_Lightning's profile (online now)


4314 posts in 4075 days

#14 posted 07-04-2010 05:50 PM

Very nice! Maybe you could strap the thing to a sheet of plywood? Don’t know if that would cost more than the insurance…but at least you get to make something from the ruins of the old.

-- Steven.......Random Orbital Nailer

View childress's profile


841 posts in 4508 days

#15 posted 07-04-2010 05:57 PM

JJohnston, good advice and definitely something I was and am thinking about.

As far as being off the ground. I know it has to be handled at some point in time, but I bet if you were moving this and picked it up, you would be cautious as not to drop. Even being end grain, this would take a big drop to break like that. must have slipped out of someones hands when transferring trucks or something…

-- Childress Woodworks

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