DIY Butcher Block Counter

The butcher's block countertop is a classically handsome and highly functional option for your kitchen counters that won't trample your budget. Due to its natural finish, you can use the butcher's block as a cutting board or prep space, and it can withstand heat from hot pots and pans without melting or marring. Of course, a naturally prepared butcher's block will take a bit more maintenance and cleaning than some plastic and stone countertops, but you can easily sand it down to a smooth finish if the surface becomes too scratched, stained or scarred. Does this Spark an idea?

Instructions

Cutting and Gluing Your Wood

1

Crosscut your 2 by 2-inch maple boards to the length that you need the countertop to be, using your table saw or radial arm saw. Add about 1/2 inch to the length. Lay each board side by side until you have enough to cover the width of your counter. The measurement does not have to be exact, as you can cut or sand it down to size at the end.

2

Crosscut the maple pieces you just cut into random sizes no shorter than 8 inches, using your radial arm saw or table saw. Rearrange the boards back into a rectangle so that pieces of different boards end up adjacent to one another. This will create the butcher's block or wood floor appearance. It is okay if the ends don't line up perfectly, as long as you added in enough extra length before you cut the boards.

3

Using your table saw or jigsaw, cut your piece of plywood to the same dimensions as your countertop. This piece will act as the support during the gluing process.

4

Place your three pipe clamps on a flat, level surface so that the jaws are open and pointed up in the air. Make sure they are spaced far enough apart to accommodate your entire countertop. Put the plywood sheet you just cut on top of the pipe clamps in between the jaws. Cover the top of your plywood sheet in wax paper.

5

Coat the sides and the top and bottom edges of your pieces of maple, one by one, and reassemble the countertop on top of your plywood sheet. All edges contacting other pieces of maple should receive a liberal coating of glue.

6

Tighten your pipe clamps to compress the maple boards together snugly. Wipe up any excess glue that was squeezed out from the spaces between boards. Place two more pipe clamps on top of the countertop, in between the three on the bottom, and tighten the jaws to provide extra compression. Since a butcher's block is essentially a long strip of laminate, achieving the proper amount of pressure is essential to its durability. Allow your countertop to dry for at least 24 hours.

Sanding and Forming Your Counter

7

Remove the pipe clamps and carefully peel off the wax paper, once the glue has dried thoroughly. Set aside the plywood sheet.

8

Use your table saw or circular saw to cut your butcher's block stock down to its actual size and straighten up any uneven edges.

9

Clamp your butcher's block countertop down to a work bench and begin sanding with your belt sander, using a coarse grit belt. Do not bear down too hard, and try to keep the sander moving continuously to ensure an even finish. Continue to sand until all additional glue has been removed and the countertop feels smooth and uniform. This process will create a lot of sawdust, so be sure to wear a respirator or dust mask.

10

Turn your countertop over and sand the other side until it is also uniform and smooth.

11

Use your router with a rounding bit to cut off the extra material around the edges, if desired.

12

Finish by hand, rubbing the top of your countertop with varying levels of sandpaper going from coarse to fine (you do not need to finish the bottom of your counter in this manner). Remove all sawdust from the surface of the counter and apply a coat of food-safe oil finish with a rag. Allow 6 hours drying time before sanding with extra-fine grit sandpaper and applying another coat. Allow 72 hours for the last coat to dry.

13

Install your butcher's block countertop and wash with soap and water before direct contact with food.