Plans for a Butcher Block Top

Lay two large F-clamps on their spine across the work surface and open them out at least 20 inches. Space the clamps around 10 inches apart. Lay 10 planks of 16-inch 2-by-2 hard maple across the spines of the two clamps. This will make a butcher block top that is 16 inches wide, 20 inches long and 2 inches thick.

Apply polyurethane glue to one face of the first piece of lumber to your right, using an ink roller to ensure total coverage. Turn the lumber so that the face with the glue is facing left, toward the other pieces of lumber.

Apply glue to one face of the next piece of lumber to your right, then turn the lumber so the face with the glue is left, facing the remaining lumber pieces. Push the first piece of lumber up to the second, so that the glued face of the first piece of lumber abuts the back of the second piece. Continue in this manner until all 10 pieces are glued together.

Tighten the clamps a little, so the lumber is pressed together but you can still move the pieces. Adjust the ends of all the pieces so that they are even, then tighten the clamps fully.

Lay two pieces of scrap lumber, that are approximately 20 inches, across all the glued planks. Clamp these pieces of lumber down using G-clamps. These pieces will ensure the glued lumber stays straight and flat.

Let the glue dry for about 30 minutes, then scrape off any squeezed out glue from the lumber joints using a metal scraper. Don’t just wipe off the glue while it is wet, as this will apply small amounts of glue to the surface of the lumber. Leave the lumber in clamps overnight.

Remove the lumber pieces from the clamps and sand both sides of the lumber flat with an orbital sander. If needed, use a planer or hand plane to help achieve a flat surface.

Cut the slab of glued lumber into 2-inch sections on a table saw, cutting along the 20-inch edge of the slab, so you end up with eight pieces of 20-inch lumber, which is made up of the glued together pieces of 16-inch lumber.

Turn all the lumber 90 degrees, so that the end grain is exposed. Glue these lumber planks together in the same manner you did the first time, with all the end grain edges facing up. Clamp the lumber together as you did the first time around, using scrap and G-clamps to keep the lumber flat as well.

Scrape off any excess glue after half an hour, then leave to dry overnight. Remove the clamps and sand both sides of the lumber slab with the orbital sander.

Read the instructions for your wipe-on varnish and apply 3 to 4 coats to the butcher block top as directed. This generally involves thinning out the varnish and applying a coat with a rag or paper towel. Generally there are 4 to 8 hours drying time between coats.