How to make a Handmade Union Jack Coaster from Scrapwood! This project is made from 99% re-used materials, and is a very fun and easy project. Not only does it catch the eye of people, but impresses everybody with the simple and easy way to make it!
So without further ado, let's get started!
• Scrapwood (red material, brown material, and white material)
• Wood Glue
• Beeswax (or any oil of your choice)
• Disc Sander (or anything that removes material quickly)
• Sand Paper
• Table saw (or any saw that works for you)
• Table saw Gage (or you can use a Protractor)
• Clamp/ Vise
Step 1: Cut Your Pieces
For the first step you'll cut your pieces. Here i'm using my Table Saw, but if you have another way to cut your wood; then go right ahead. Here I cut my slices in these dimensions:
White wood No.1: 1/8in. • 1/4in. • 5in.
White wood No.2: 1.4in. • 2/4in. • 5in.
Red wood No.1: 1/4in. • 2/4in. • 5in.
Red wood No.2: 1/4in. • 3/4in. • 5in.
Dark wood: 1/4in. • 1in. • 2in. (x4)
Once cut, continue to the next step.
Step 2: Glue the First Piece
Now that your pieces are cut, you will glue up your first piece. Here I used Gorilla Wood Glue, but any glue would work. Make sure to use plenty of glue for this step, you want some squeeze out. Once glued, let it dry for the given amount of time depending on the glue you use. I let mine dry for about 24 hours before working with it again. Here I glued it up in this order:
Brown, white, red, white, brown. (see images above)
Step 3: Mark and Cut
Now that your piece is all glued up, you can start on the pattern. Here I took my Table Saw Sled Gage, and turned it to exactly 53°. Then, I put the flat face to the wood and began marking my piece to about 1 in. wide, and marked the tip where the beginning of the white stripes start, and end. (see images above) Then, I took it to my scroll saw and cut it out. You can do this with a table saw if you'd like, but I chose to use this. Once you cut out the strips (as seen in images), cut off the tips where the stripes begin and end.
Once cut, you're ready for the next step.
Step 4: Glue Your Pieces
Now that your strips are cut out, it's time to glue them up. Here I took some thin Maple (1/8in. • 1/4in. • 1in.), and glued it to the tips of the strips. Make sure before glueing, to check to see if the align correctly. That each stripe comes together to make a X. (see images above) Use quite a bit of glue for this step, and let set for about 3 hours.
Step 5: Assemble Your Stripe
While your other pieces are drying, you can glue up your center stripe. Here I took some Paduak (Red Stripe No.2) and glued 2 (1/8 • 1/4 • 3) pieces to each side. (see images above) As always, use quite a bit of glue; and let set for about 3 hours. You will need to make 2 of these.
Step 6: Glue the Flag Together
Now that all your pieces are cut and ready, it's time to glue up the flag. I started by glueing both X stripes to either side of the the strip made in the previous step. (see images above) I did this to both strips. Then, once you do that; Take a piece of Paduak/ red wood (1/4 • 3/4 • 3) and put glue on either side. Then, glue both side pieces to the center strip. (see images above) Once done, clamp it together and let it dry for 24 hours.
Step 7: Make It Symmetrical
Now that it's dry, take something with the same diameter as the width of it, and trace a circle unto your wood. I cleaned up the piece before tracing by sanding it down on a disc sander. (see images above) You want something with about a 5 in. diameter. Once traced, take it to a scroll saw (or coping saw/ jig saw) and cut out the circle. Try to be as precise as possible.
Once cut, drill a 1/8 hole through the middle of the the piece. Then, take it to a sander and pin it down as firm as possible up against the sander, and start slowly turning it; what this does is it rounds it off perfectly. Once done, you're ready for the next step.
Step 8: Sand Your Piece
Now that your piece is symmetrical, take it to some 400 grit sandpaper, and work up to 1000 grit sandpaper. Take your time with each grit, and be sure to remove as many scratches as possible. I spent about 5 minutes between each grit and took my time getting each scratch out from the grit before. You can take it to higher grit if you want, but i wanted a Matte Finish. Once you're done sanding, you're ready to Oil it.
Step 9: Oil Your Piece.
Now you're ready to oil your piece. Here I used some Beeswax, but if you have a oil that you would like to use; go right ahead. I went with Beeswax because I feel like it takes the true color of the wood out, and exposes the grain patterns and everything else perfectly. Beeswax is also Food Safe, so you can oil your kitchen-ware with it if you'd like. I applied the oil by dabbing it on with my finger, and then started rubbing the oil into whole piece. you don't need much Beeswax, so little is okay. Once your piece is finished, you're done!
Step 10: Finished!
Now your piece is finished! This was a very fun and easy project, and i hope you all enjoyed it as much as i did. This is a very great way to re-use scrapwood, and a very cool Before-and-After of how you can simply turn trash to treasure. I had a great amount of fun making this project, I hope you found this helpful!
Thanks so much for viewing, and as always... 'Create Something'.