Turning a 2x4 into 24 beautiful coasters

Summary

In this DIY tutorial, the creator demonstrates how to turn a single 8-foot 2x4 into 24 stunning coasters. Starting with the selection of wood, the process involves cutting, sanding, and finishing the coasters using a table saw, router, and various sanding techniques. After applying multiple coats of polyurethane, the coasters are polished to achieve a glass-like finish. The video emphasizes the importance of the detailed finishing process for durability and aesthetic appeal, and the coasters are tested with cold drinks to ensure their functionality. This project makes for a fun, hands-on, and rewarding woodworking task.

Takeaways

• 😀 Found a unique 2x4 at Lowe's with interesting color due to sap flow from a dead tree.
• 😀 The coasters are designed to be 3.5 inches by 3.5 inches, with 4 coasters per 16-inch length of the 2x4.
• 😀 A table saw was initially used to cut the wood, but a safety issue led to using a planer instead.
• 😀 A router table was created by flipping a router upside down to round off the coaster edges.
• 😀 The coasters were sanded with 220 grit, followed by 320 grit sandpaper for a smooth finish.
• 😀 The coasters received two coats of polyurethane, with careful sanding between coats to ensure a smooth surface.
• 😀 Used a creative method with cardboard cylinders to prop up coasters during the finishing process.
• 😀 Wet sanding with 600, 1200, and 2000 grit sandpaper was done to get a smooth, glossy finish.
• 😀 Car polish and wax were applied to the coasters for an extra smooth, shiny, and waterproof finish.
• 😀 The finished coasters were tested with cold beverages, showing effective moisture resistance and durability.

Q & A

What inspired the creation of these coasters?

The creator was inspired by a piece of wood they found at the bottom of a bundle of 2x4s at Lowe's. They were drawn to the unique color of the wood, which was likely due to sap flowing back down the tree after it died.

What dimensions were the coasters planned to be?

Each coaster was planned to be 3.5 inches by 3.5 inches, as the 2x4 used was 3.5 inches wide.

Why did the creator choose not to cut the 2x4 in half at the beginning?

The creator initially tried to split the 2x4 in half to get two equal halves for the coasters. However, they experienced kickback from the table saw, which led them to abandon that approach for safety reasons.

What adjustment did the creator make to continue with the project after the failed cut?

After the kickback incident, the creator used a planer to smooth down the pieces of wood before returning to the table saw to cut the coasters to the final size.

How did the creator smooth the edges of the coasters after cutting them?

The creator used a router with a 1/4 inch roundover bit to smooth the edges of each coaster, creating a smoother transition between the sides and the bottom.

What tool did the creator use to build a makeshift router table?

The creator used a job horse, a type of sawhorse with a 24-inch clamp, to hold the router upside down, effectively creating a makeshift router table for the project.

What finishing techniques were used on the coasters?

The creator sanded the coasters with 220-grit and 320-grit sandpaper, then applied polyurethane. They also used wet sanding with 600, 1200, and 2000-grit sandpaper, followed by car polish and wax to achieve a smooth, shiny, and waterproof finish.

What purpose did the cardboard cylinders serve during the finishing process?

The cardboard cylinders were used to prop up the coasters, allowing the creator to coat both sides at once without the coasters sticking to the surface as they dried.

How did the creator test the coasters' functionality after finishing them?

The creator gave the coasters to a friend as a parting gift, who tested them by placing both a cold adult beverage and a glass of iced water on them. The coasters worked well in both scenarios, proving their effectiveness.

What did the creator learn from this project?

The creator learned the value of attention to detail in woodworking, particularly when it comes to sanding and finishing. They also found that small projects like this can be rewarding and are a great learning experience, potentially even worth mass-producing and selling.