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The series for this project - here is quite in-depth, so I won't recreate it here. I'll just sum up…

I got a stack of slats from a pallet from a local bearing shop all cut up nicely in a stack of 14"-16" pieces. Sorting them, I found many that appeared to be kinds of oak. I ran these over the jointer, through the planer, and cleaned up their edges, then glued them up into a block. In the process, I figured out a few boards were white oak, many more were red oak, and as many more were a yellow wood I've not yet identified.

The glued-up block was jointed and planed again to parallel and square, ends cut off and saw's unfortunate burn marks sanded away on the belt sander, set up to perfect 90°s again. Now I had a perfect block in the neighborhood of 3"x4"x13.75". I took pictures and used them to model a replica in Google SketchUp. Now I could cut this apart virtually on my PC and try out different configurations of blocks, including end grain vs. long grain boards. I selected a style and cut the block up into 2" thick chunks with a dull 1", 2TPI blade in my band saw, burning the cut faces to black.

Running the edges on the belt sander to flatten them (hard to get perfect), then gluing these together gave me an ugly, lumpy mess, but then running the router sled over it got it perfectly flat, and to an even thickness, flat to less than 1/128th of an inch deviation across the entire surface - not important, but nice to see.

I ran it again over the jointer to get one long and one short edge sharp and at 90° to the faces, then ran it through the circular saw on a miter sled to get the opposite edges parallel. One more kiss-pass on the jointer to remove that pesky saw burn and I had another perfect block with a new set of dimensions.

I ran it around the router table with a large roundover bit (forget the size), sanded it all up with an ROS and hand sanding down to 220 grit, marked and drilled holes for the rubber feet, hit it with the brand, oiled up the bottom with butcher block conditioner, screwed in the feet, flipped it over, and have since been conditioning the top and sides with the conditioner in multiple coats applied about once an hour, probably to a limit of 5 or 6 total coats before I put it up for sale online.

The final cutting board is 6-3/4" x 8-5/8" x a bit over 1.75" thick. It stands about a half inch higher on its rubber feet.

Thanks for reading! The whole process only took about 3 days of light work. Not bad! Having the planer back is quite a help.

Gallery

Comments

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Gary free is good! It looks great! Haven't talk to you in a while, hope all is well. Been busy remodeling my backyard in between the rain and company from the East Coast! Talk to you soon, keep making saw dust!
 

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Nice cutting board. I've found a source for free pallet wood also. The species of wood that I have identified so far are, white oak, red oak, poplar and maple. That "yellow" would you mention above is probably poplar. It often has a yellowish color to it. If it has any green streaks in it, it almost certainly is poplar.
 

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YAY for reusing old stuff. Also I love how big and thick the cutting board is. Nice big butcher block style.
 

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Congrats on the recycling. Cannot get pallet wood here, it's all pines & split up..Great project.
 

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Free pallet wood works for me Gary.

Those boards cam out real nice.
I think I'm going to try some of those.

Good job.
 

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Gary, Great wood and really nice block! I like your brand on the bottom which adds a nice personal touch. Where do you get them?
 

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Awesome job on your cutting board. I know exactly the work that went into making that cutting board, and you did a outstanding job. I had a old cutting board giveing to me and some one submerged it in water and it was cracking where the glue was. Well i cut it and planed it and joined it. It was a job. You did a superb job.
 

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I've always enjoyed using reclaimed wood for projects. What a creative use for the sturdy oak you found!
 

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Nice job and thanks for the idea. I saw your post on FB and went to see what I had when I got to work this am… to my disbelief I have two with black walnut slats mixed with oak slats… I cant believe I haven't look at these sooner. We get them all the time and leave them for guys to pick up for free. Oh well now I know…
 

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That is a good looking piece of scrap wood! Very thick, I love it!
 

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Great use of pallet wood. Real nice cutter.

Keep it up.

Scrappy
 

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I got some really nice birdseye maple and some white oak from some pallets a few years ago. I decided then whoever it was that invented the "Spiral Nail" should firmly and repeatedly pimp slapped.

Unless you are building a boat, you should never use ring shank or spiral nails for ANYTHING that EVER may be taken apart by some poor soul! Ha ha!

BTW< Nice board! I too know the work involved in making these!
 

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Nice work. Just hope the yellow wood is not poison oak.lol But seriously, I hope it's not some toxic species of wood.
 

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Thanks for all the kind words, folks!

I agree about those spiral nails, Jerry!

CSlabon - Don't be a downer ;)
 

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I love free pallets… have a few items I've made from the reclaimed wood.
 

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We get free pallets from our local hardware shop. They are happy for customers to take them away. Some are made of nice pine which can be reused, and others are cheap particle board which has limited use.
Great chopping board by the way! Well done.
 
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