I made these simple sandwich boards at TechShop SF (www.techshop.ws)
Step 1: Cut the Wood
Cut your wood. I started with a pine board 1" x 10" x 8', and was able to cut 8 boards into 1" x 10" x 12". Note that pine is extremely soft, and is will dent. It is not ideal for a cutting board, but no cutting will be done on these simple boards, and they will be lined with paper whenever used.
Step 2: (Optional Step: Create Template)
This step is optional. I created a template in Illustrator to mark the cut lines in the boards, and to etch my logo with a laser cutter. You can do this by hand (draw out the shape with a pencil), which works just as well. I did this because it was faster and I have access to a laser cutter at TechShop.
Step 3: (Optional Step: Laser Cut the Lines)
Laser the cut lines
Step 4: Cut Out the Pieces
I made the main cuts with a bandsaw
Step 5: Refine Your Cuts
I then used a scroll saw for the tighter curves.
Step 6: Sand Down the Edges
Carefully sand down the edges and corners. I used a belt sander, but you can also use a sanding block or sand paper.
Step 7: File Down the Corners & Finish
Its hard to get the corners and tight curves with sandpaper, so I used a wood file. I finished the boards with "GOOD STUFF" finish, which makes it water proof. They are now ready for use!