How do I create my own wooden slats?


 
John-NY

John-NY

TVWBB Pro
I have all the tools to do this, I just need some guidance on the order of operations and materials needed.

This is my "in my head" plan for a Genesis 1000:

1) Buy a slab of wood
2) Measure and cut the wood to size with my table saw and miter saw
3) Optional Step: Use a round-over bit on my router to soften the edges? Is this recommended?
4) Take each of those cut slats and random orbital sand them one by one
5) Apply some kind of finish like polyurethane or whatever
6) Done

Is it really that simple? Am I missing anything important?

I have all these tools from installing trim in my house, etc., but I've never used them for a "woodworking project" before.

Any help or pro-tips are appreciated.

Thanks!
 
It only sounds just that simple, to me lol... I have yet to do it myself. I think the most tedious part is the staining and spacing of the slats. I am not the best with wood so when I take that task on, I know it is going to be a real goat rope. Thankfully I have a friend who will cut all the slats for me!
 
If your gonna buy a slab and cut that into slats then a thickness/edge planer would be advisable.
If your gonna by S4S ( square four sides ) like a 1x2 0r 1x3 or 1x4 then no need. Round over bit on a router or a hand plane to knock down the sharp edge. If you do it on a router then you prolly need a table mount unless you have a small one handed trim router.
 
I will call in a favor from my cabinetmaker/banjo player buddy and bribe him with a bucket of pulled pork!
It’s really easy.
Actually, I could do it, exactly how you are doing it but, I have no tools or shop space. A sixpack of something good, some snacks and an hour at his fully equipped shop or a full day getting frustrated (no tools or space) then just have the boys over for cocktails and something to fill bellies! I’m really lucky!
I do know it too!
 
I have always used 1x2s that are readily available in cedar and, depending on your location, some other nice options. I have bought red oak and mahogany boards at my local Menards.

The only gotcha is that theses boards are slightly thicker (up and down) so some planing or serious sanding will be required if you want to get to “stock” thickness. Some actually prefer the slightly higher shelving that helps protect the metal z-bar.

Last important comment: Do NOT use polyurethane as it is meant only for inside applications. Use a quality spar urethane or perhaps a deck type treatment.

Starting with 1x2s would seem faster and easier. The original slats did not have well rounded corners. I think a light sanding is adequate to take off the sharp edges. However, we have seen some gorgeous woodworking by members here who have the right tools and know how to make stunning wood slats. So a custom look could certainly be an appealing way to go.
 
timothy said:
If your gonna buy a slab and cut that into slats then a thickness/edge planer would be advisable.
If your gonna by S4S ( square four sides ) like a 1x2 0r 1x3 or 1x4 then no need. Round over bit on a router or a hand plane to knock down the sharp edge. If you do it on a router then you prolly need a table mount unless you have a small one handed trim router.
Click to expand...
So I actually sold my thickness planer. I also only have a large plunge router but maybe the soft edges won’t be necessary anyways
 
John-NY said:
So I actually sold my thickness planer. I also only have a large plunge router but maybe the soft edges won’t be necessary anyways
Click to expand...
As Jon mentioned, the original slats weren't rounded over. When I made my first batch of slats I copied the durawood slats that were already on my grill. Those do have a rounded over profile which I prefer to the original design. You can do it anyway you want to as long as you're happy with the results. Finishing them and setting the spacing is the most tedious part of the job for sure.
 
John-NY said:
Is there a quick and dirty trick to spacing setting?
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I think so, at least it makes sense to me. It's easier if you have an odd number of slats, like the end tables that have 5 slats. Screw two slats at both ends of the Z-bar (slats #1 & #5). Screw 1 slat in the exact center (slat #3). Evenly space slat #2 between slats 1 & 3 and evenly space slat #4 between slats #3 & #5 and screw them down. Done.

Other than finding the location of the center slat #3, you can just eyeball the rest. Nobody will know (or care).
 
Simple???? LOL. With all the tips, tricks, and advice you got, it feels like it would be a massive undertaking.

Will some basic wood working skills, you should be fine. Good luck and let us know how it works out.
 
Steve Hoch said:
I finally made a jig to do it quickly and accurately, but otherwise you can use anything as spacers that give you the desired gaps. I've seen people on here use nuts, quarters, scraps of wood. My best tip would be to figure it out with an existing table.
Click to expand...

Can you post a pic of your jig? I’m extra curious what it looks like!
 
At least in my opinion If the project is worth the time. It's worth putting in the time to do it right and make it perfect. I don't like to rush it or take shortcuts to compromise the quality. I enjoy every part of the process along the way.
 
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