Fivebraids Custom Woodworking, Inc.

Butcher Block topped Kitchen Carts

 

(Click on any image for larger version)

 

This is a pair of heavy duty kitchen carts that were built and placed in our studio. They are intended for anyone that doesn't have the room or need for our popular full-sized butcher block kitchen islands.

 

One is solid Hard Rock Maple, the other is solid African Mahogany with Walnut accents.  They feature 3 1/2" thick butcher block tops, finished with mineral oil and beeswax, that are intended to be used as cutting surfaces. 

 

The bases feature mortise and tenon construction to stand up to years of use.  The bases are finished with several coats of lacquer for durability. They both have removable lower shelves.  They also have dovetailed drawers on 100 pound ball bearing slides.

 

These two both measure 25" x 25" wide by 36" high (standard kitchen counter height).  They can be ordered in whatever dimension you might need.

Construction Details

 

Solid two inch thick Hard Maple and African Mahogany was milled.  Some became the sides of the carts.  The remainder was glued up to create the blanks for the legs, as well as the blanks for the butcher block tops.

 

The butcher block top blanks were sanded flat in the wide belt sander.  To add a little visual interest to the Mahogany top, another smaller blank was created with some very dark African Mahogany and some Walnut.

After flattening, the blanks were cross cut and then glued up to form the actual butcher block tops.  The tops were securely clamped and left to dry overnight.

 

With both tops built, it was time to concentrate on the bases.  Tenons were milled on the ends of all the side components, as well as the supports for the lower shelves.  Matching mortises were milled into the legs.

 

Since the front of each cart would contain a drawer instead of a mortise and tenon-ed side, additional support was needed. Dovetails were hand cut on to the end of stretchers to span the legs above the drawers, with corresponding dovetail pins (sockets) hand cut into the top of the front legs.

 

To add a little visual interest to the legs, sets of three flutes were milled into their faces.

 

 

 

With all the mortises, tenons, and dovetails milled on all the parts, it was time to assemble both bases.  Industrial strength, double locking  rubber casters were also mounted.  (Engaging the lock on a caster prevents the wheel from turning, as well as the caster from swiveling.)

 

These sturdy carts needed drawers equally as sturdy, so they were built using traditional dovetail construction.  Rabbetted half-blind dovetails attach the drawers sides to the fronts, while through dovetails attach the sides to the backs. The drawer sides and back were cut from a single board, with the grain running continuously around the drawer. For a little additional visual interest on the African Mahogany drawer, the sides were made from a single piece of Walnut.

 

 

 

Wide Maple and African Mahogany boards were selected for the removable shelves.  These boards were ripped into thin strips, making sure to keep them positioned as they were before ripping.  The result is quite obvious, showing the continuous grain matching across the shelves.  Supports were glued and pinned on the under side of each shelf.

 

While the bases, drawers and shelves were in the finishing room getting several coats of lacquer applied, a few finishing touches were needed to complete the tops. 

First, both tops were soaked with water to raise the grain.  Once dried, both tops were hand sanded to get them perfectly smooth.  The grain raising with water helps prevent any grain raising when the tops get soaked with mineral oil just prior to being installed on the bases.

 

 

Next, both tops had to be drilled to receive our trademark medallions. That's not as easy as it sounds, since each of these tops weigh over 50 pounds!

 

With the medallions installed, and a quick final hand sanding, it was time to soak both tops with food-safe mineral oil.  This soaking took place over three days, and took over a quart of mineral oil!

 

Since these carts are intended to be moved around, and they're quite heavy, a method to very securely attach the tops to the bases had to be devised.  Holes were drilled into the underside of each top.  Threaded brass inserts were then installed into the holes.  These threaded inserts are made to receive 5/16" machine bolts. 

 

 

 

Steel brackets were attached to the inside edges of the bases. Oversized holes were drilled in these brackets to allow for any future wood movement.  Once attached using five 5/16" bolts, there's no need to worry about the top coming loose when it's used to push the cart around.

 

 

The final step was to deliver the carts to the studio.  Before attaching the tops in the studio, both of them were given a thorough rubbing with our "Wood Butter", a custom blend of mineral oil and natural beeswax. The working top surfaces were given an additional coat of wood butter once the tops were bolted in place.

 

Many variations of these carts can be made to order. You can order a cart made to whatever dimension you'd like.  They can be made without drawers, or with multiple drawers.  You can choose a different species of wood, or even ask that the bases be painted to match your kitchen decor.  Let us know what you have in mind and we'll do what we can to make your dream come true.