Intro: End Grain Butcher Block Door
So because I'm apparently an idiot, I thought this project would take just about 2 weeks. 2 months later, I am sick and tired of end grain, but I have what I think is a pretty kick ass door. I made it at Tech Shop (and thank god I had Tech Shop because otherwise, this damn thing would have taken 5 times as long to make) http://Techshop.ws
Step 1: Cut a Bunch of 2x4s
Using the miter saw, I cut down about 12, 8' 2x4s. This gave me approximately 4 million 2.5" pieces.
Step 2: Glue the Pieces Together
Using the clamps at Techshop, I glued pairs of 2x4s together.
Step 3: After Gluing the Pieces Together, I Then Glued More Pieces Together
Glue the pairs of 2x4s to other pairs of 2 x 4s. At this point you can use whatever pattern you like. Your goal is to have rows of wood the width of your final door.
Step 4: Square the Rows
Run the rows through the table saw so that they are square and will glue up properly.
Step 5: Keep Gluing, Start Hating Life.
You will eventually end up with a slab of pieces. This is where the design of the door becomes important. If you want spaces in your doors like mine eventually has, you need to plan ahead and make the slabs the correct height. After you have the slabs, use the shop bot to level the slabs.
Step 6: Lay Out This Mother...
Now you need to lay out the slabs and start gluing some more....
Step 7: Reinforce the End Grain Pieces
Attach wood on the perimeter of the door so that the end grain pieces can be supported. If you don't do this the door will likely fail.
Step 8: Finish of the Door
If you want, add glass to the openings and finish off the project by leveling the door on both sides and you're set.