Salvaged 1950s Douglas fir turned into a butcher block counter

Oct 26, 2026 Last reply: 1 day ago 3 Replies
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The detail that caught me off guard is the oil schedule: three coats of tung oil underneath and seven on the working surface. That is a lot of patient brushing, and it shows in the smooth amber finish on the finished piece. Salvaged lumber milled back in the 1950s ending up as a food-safe looking kitchen surface is a genuinely satisfying outcome for old boards that most people would have burned.



The construction approach is well thought through. Every board first went over with a metal detector to find hidden nails, since hitting one would have chewed up the blades, and the contaminated sections were then cut away on a miter saw. From there the boards were ripped into 1.5-inch strips, turned quarter-grain up, and biscuit-joined with glue into sub-panels sized to fit through the thickness planer. Only after planing those sub-assemblies were the biscuit slots cut along the main joints for the full glue-up under bar clamps. Breaking it into planer-sized panels seems like the smart way to handle a top this size with benchtop machines.



The sink work stands out too. A jigsaw roughed out the opening, then the sink itself was clamped underneath with brackets and screws to act as a guide while a bearing flush-trimmed the edge clean. The bowl was bedded in silicone with mounting clips, and the faucet hole was drilled with a Forstner bit. Edges got a 1/8-inch roundover after sanding, and the top was belt sanded to scribe against the wall.



The one open item is that this piece is only part of the counter. A larger peninsula is still to come, with a second part planned for late summer or fall of this year, so the full picture is not on the table yet.



Project by Les Mason Woodworks. Watch it on their YouTube channel:

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The seven coats on top versus three below is the choice I keep coming back to. It is a sensible split in my view, since the working surface takes the wear and the underside mostly needs protection from moisture coming up through the cabinets. It does trade drying time for durability, and waiting out all that oil before the sink went in must have taken discipline.

I am curious about the scribing step. Belt sanding the back edge to fit the wall sounds like it could wander fast on a wide top. Did the maker mark a pencil line first and work down to it gradually, or was it more of a test-fit-and-repeat process against the wall until the gap closed?

One variation worth considering for the peninsula: since it will be the bigger work surface, the maker could add even more tung oil coats on the top than the seven used here. The amber finish on this piece already looks like it can handle a kitchen, and a heavier build on the section that gets the most use seems like a cheap insurance policy with the same product already on hand.

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