PROJECT BUTCHER BLOCK FRONT SHELF - PART 1 of I HAVE NO IDEA?!?
So I ordered a butcher block counter top piece from Home Depot. Gotta commend them on their service, I got it the next day. I bought a piece that was 50x25x1.5". I'm going to stain it and coat it. It won't be used as a cutting board, only as a shelf. I am planning to add a front and side shelf from this piece and will have a little bit left over that I'll make into an outdoor cutting board or a wheel chock. Whatever floats my boat.
Now wood working isn't exactly my thing. I prefer metal working, but I have most of the tools to do woodworking, so I decided to get out my track saw and router kit I bought from EurekaZone years ago. My poor Dewalt router has some surface rust on it I'll need to clean up, but my Hilti soft-start saw with a fresh diablo blade was sitting in the bag just ready for another sawing adventure.
I have not decided on the exact dimensions for the front shelf, so I've left it 50" long for now. It' likely will be trimmed down to around 40", but we'll see. I decided on 12" in depth and I'm going to keep it away from the cooking chamber by 1-1.5".
If you remember those folding hinges I bought, I ordered two more but in 12", versus the 10" I'm using right now. I'm going to use the 10" versions for the side shelf. After doing my layout, I cut two dados into the bottom side of the shelf to reduce the height of the shelf when attached to the brackets. The dados are 3/4" deep so I still have enough meat to left to attach the shelf to the brackets.
After I fit it to the Smokefire, I noticed that the handle was awfully close to the top of the shelf. I took a look at the handle assembly and noticed that if i removed it and drilled out the locating dowel hole with a 1/4" drill bit, i could flip the handle upside down. That gave me enough room and saved me from modifying the folding brackets. At best I can lower the brackets 1/2" by redrilling them. Flipping the handle was way easier and can be put back to the originate state with no issues.
Test fitting: The handle was too close...
Let's mod that handle:
Oh I can work with that. I'm done for today because I had to also fix a broken fence post and I managed to get my RealID from the California DMV. Busy day for sure with a trip to Home Depot mixed in. I'll keep working on this as time permits this week. I plan to determine the length dimensions, round the front corners with a jigsaw, round the edges with a router and possibly put a beer can holder in it, because why the heck not? Once sanded, then I will be standing it with Cognac colored stain and will then coat with marine spar.
Please join me on a future part of the front shelf project.
