Today I started on the desk for the studio nook. The final product should be a 3' x 6' desk top, with a raised studio back portion for gear, monitors, etc. I decided that I wanted to make it with a butcher block top, so it can do double duty as both a good looking desk AND be usable for working on guitars. It should be sturdy, take a beating, and be able to be refinished if/when needed when things like soldering go badly.
Making a top like this isn't hard, but it can be tedious. Step one was to take a whole bunch of hard maple pieces down to 3/4", and 3 wide. They're mostly 6', but some are a bit longer and will be cut to closer to finish length before glue up. 36" of width at 3/4" each is somewhere around 45 boards, which looks like this:
I sorted them by size there, so I can start gluing up the 6' first. When gluing up this much, there's a few things to take in mind. First, that's TOO much weight to do in one go. Secondly, you have to work quickly and smoothly, or you'll have it get ahead of you. Lastly (and most importantly) getting the boards glued up with zero (or as close to zero) gap is very important to the final look of the top. Since I'm still doing this purely at home, and have to stick to "homeowner" clamps and such, I'm breaking it into 3 sets. Each group will be 15 boards, and the final step will be to put the 3 together.
Step one: set up the straight clamps, dry fit the boards, and make sure it's ready for glue. For scale, this is 6' long, 3" deep, and 12" wide.
Step two: cover one side of each board in glue. There's so much gluing that needs to happen quickly and accurately, I'm using a 4" paint tray and roller. Lay out 4 boards, roll glue, stand them up in place, repeat:
Step three: clamps, clamps, and more clamps. I generally say that clamps aren't to hold pieces in place, it's to hold pieces that are already in place together while they dry. In this case though, it's the best attempt to remove any gaps or voids along the length. This is one of the main reasons for breaking this into 3 rounds. Even with clamps every few inches, there's only so much pressure they can exert.
Tomorrow I do another 15, then the last 15 on Thursday. Hopefully Friday I can glue the 3 sections together into one top. I should be leveling and cutting to final dimensions by the weekend.