Building an End Grain Cutting Board

In this video, I use some of the scrap wood in the shop to build an affordable end-grain cutting board. This helps recoup the cost by reclaiming the scrap wood and diverting waste from the landfill.  Handcrafted in Colorado.

Summary

Efficient Scrap Wood Repurposing for Cutting Boards

Brian discussed his efficient process of repurposing scrap lumber into cutting boards, emphasizing the importance of speed and minimizing waste. He detailed his use of tools like a drum sander and router table to streamline the process, and highlighted the benefits of standing the wood upright during routing to reduce tear-out. He estimated that he saved around $500 worth of wood from the landfill and invested 20 hours in creating 15 boards, which he plans to sell for around $100 each, expecting to make around $70 per board after accounting for costs. He also suggested that other small woodworking businesses could benefit from repurposing their scrap wood into unique items.

Maximizing Profits by Turning Scrap Wood into Cutting Boards

Every woodworking project generates scrap lumber—pieces you paid for but often end up throwing away or cluttering up your shop. Instead of letting that valuable material go to waste, I’ve developed a system to transform scrap wood into high-end cutting boards that sell for around $100 each. Here’s how I do it efficiently while maximizing profits.

Step 1: Collecting and Organizing Scrap Wood

The process starts with managing scrap lumber. As I work, I gather all my offcuts and bring them to the miter saw. I have a mark set at 18 inches from the blade, which I use as a reference to cut all scraps to a uniform length. Any remaining unusable pieces go into a bucket, and when it’s full, it gets tossed.

The 18-inch pieces go into a box under my miter station. Once that box overflows, it’s time to move to the next step.

Step 2: Jointing and Sorting by Thickness

On slower shop days, I take all the scrap wood and joint each edge to ensure clean, glue-ready surfaces. As I work, I sort them by thickness—not because I want them all the same size (I actually prefer random thicknesses for a more interesting look), but because it speeds up the planing process. Running boards of similar thickness through the planer in batches saves time and reduces tool adjustments.

After planing, I sort them again by wood species to prepare for the next phase.

Step 3: Random Panel Glue-Up (Inspired by Matt Cremona)

I got the idea for random wood, random shapes, and random species from woodworker Matt Cremona. However, I keep mine simpler for efficiency.

Here’s how I do it:

• I screw a scrap block to my workbench with a pencil mark indicating the desired panel width.

• I grab random species and sizes, arranging them until I hit that width.

• Once the arrangement looks good, I glue them up into a panel and set them aside to dry.

By keeping the widths roughly the same, I minimize planing time later.

Step 4: Planing and Trimming

After the glue dries, I run each panel through the planer to achieve a uniform thickness. I don’t force them all to the same size—just enough to clean up both sides and ensure they’re parallel.

Since planing can create snipe (an uneven cut at the ends), I square up one end on each panel to remove it before moving forward.

Step 5: Taking It to the Next Level—End Grain Cutting Boards

At this point, I could stop, sand the boards, apply a finish, and sell them as long-grain cutting boards. But I prefer going the extra mile to create end grain boards, which are more durable and visually striking.

Here’s how:

1. Slice the panels into strips (about 1.5″ wide).

2. Flip them on their ends to expose the end grain.

3. Reglue them in a randomized pattern, ensuring each board is unique.

Again, I keep the lengths slightly oversized so I can trim them perfectly square later.

Step 6: Sanding, Trimming, and Routing

Sanding is the most tedious part, but a drum sander speeds things up significantly. After sanding, I:

• Trim the boards parallel at the table saw.

• Square up the ends.

• Add a decorative roundover at the router table (I stand them upright to minimize tearout).

Step 7: Finishing for a High-End Look

For the final touch, I apply a hand-rubbed oil finish. My current choice is Tried & True Varnish Oil, but I plan to test other options in the future.

Application process:

1. Brush on a liberal coat.

2. Let it sit for an hour.

3. Buff off the excess.

4. Let it dry overnight.

5. Apply a second coat for durability.

The Profit Breakdown

• Materials saved from landfill: ~$400–$500 worth of scrap wood.

• Total boards made: 15.

• Time invested: ~20 hours.

• Selling price: ~$100 per board.

• Profit per board after expenses (glue, finish, sandpaper, shipping): ~$70.

Final Thoughts: Is This a Full-Time Business?

Honestly, making cutting boards alone probably isn’t enough for a full-time income—competition is fierce, and it’s easy to get caught in a price war. However, if you have a strong brand or social media following, you can stand out.

For small shop owners, repurposing scrap wood into sellable products is a fantastic way to maximize profits and reduce waste. With a little creativity, you can turn what would’ve been trash into a solid side income.

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