Instructables

Cork Board Project phase 2

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Picture of Cork Board Project phase 2
I made this at the TechShop (www.techshop.ws) in Menlo Park.

This project continues the "Cork Board Project" described in a previous Instructable.

The whole project is to build several cork boards as Christmas or birthday presents. Each is a plywood board with a hardwood surround. It has two rows of corks glued around the edges, lying flat, and a square of half corks (cut using the jig described in the previous Instructable) set vertically in the middle. The wood surround is 3/4" by 1 1/2" and may be varnished.

The vertical (half-)corks show only their ends, so they can be of uninteresting origin. The horizontal corks show their winery and should be interesting and varied.

In this phase 2, we check out the procedure of building one board, to eliminate any "wrinkles". See the finished product below.
 
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Step 1: Tools and Materials

Materials:
Plywood sheet 1/4" thick and 15" square; new stock.
Plywood sheet 1/2" thick and 20" square; appearance unimportant, could be scrap.
Plywood laths (4) 1/4" thick by 1 1/2" wide by 15" long; straight, appearance unimportant.
Oak board 3/4" by 1 1/2" by 6' long; new stock.
4 wood boards 1 1/2" square cross-section by at least 19" long; straight, appearance unimportant.
60 corks of various origins.
161 half-corks.
Wood glue.
Screws.
4 bolts (3/8") by 2 1/2" long.
1" (thin) nails.
Polyurethane (optional).

Tools:
Table saw.
Miter saw.
Bandsaw.
Drill press and set of bits.
Clamps.
Screwdriver.
Light hammer.
Try square.
Cork-cutter jig (previous Instructable.)
ShopBot (optional).

Step 2: Preparation (step 1) - make the central board

Measure several corks to find the average diameter. Design the board to hold the desired number of corks. In this design there is a central rectangle (10 3/4" by 10 3/8") of vertical half-corks and a surround of two rows of corks laid horizontally.

Cut a 14 3/4" square of good 1/4" plywood, using the table saw. (Check the adjustment of the table saw first.)
These come out really nicely - at first I couldn't figure out why they were all different colors...then I thought about it for a second... Thanks for the share!