The Discovery:

A few months ago, I woke up one morning, poured my coffee, and was incredibly disappointed to see that my cutting board exploded! OK so maybe it wasn’t all that violent but it was cupped like crazy and had a very large split. Upon further inspection, I noticed a bit of trapped water in the center of the underside of the board. Now the thing to remember about end grain cutting boards is that even after finishing, they will still soak up moisture like a sponge. So standing water is your cutting board’s Kryptonite!

What Happened?

So how does the split actually occur? Well let’s think about what happened. The water soaked into the center of the board and as a result, the center “squares” swelled and expanded. Because the moisture was in the center only, the wood in the outer perimeter did not expand. So something had to give. The resulting crack is really nothing more than pressure relief. Think of it like surrounding a piece of solid wood in a frame. Eventually, the joints in the outer frame will open up if the board in the middle expands.

The Epoxy Fix:

The first step in repairing this disaster simply involves waiting. After a few weeks, the board flattened out and the crack closed up almost completely. But the gap was still big enough that I wanted to use a gap-filling glue, so epoxy did the trick. Now I know what you are thinking. Is epoxy food-safe? While I have heard that food grade FDA-approved epoxies do exist, I have never seen them. And I can definitely say that the West System Epoxy I use is not FDA-approved. So why would I use this on my cutting board? Generally speaking, its the same logic I subscribe to when discussing the safety of film finishes. That is, once cured, the product is inert. In other words, its not chemically reactive and its not actively leaching chemicals under normal room temperature conditions. Furthermore, the crack represents such a small area that actual food contact would be absolutely minimal. Now while I am not prepared to tell you epoxy is completely food-safe, I will say that I consider cured epoxy safe enough to use on a small crack on MY cutting board. Ultimately, the final decision is yours.

Want to make an end-grain cutting board like this? Check this out!

In this episode, I go over some pre-finishing tips and finish the inside of the trunk. I then go through the entire assembly and glueup process from start to finish. I then discuss the trunk’s lid, which is different from the original plan. You can download a Sketchup plan for the lid below. Once the lid is glued up, I realize that rushing through this project has resulted in a number of errors. So I fix them. I know how you guys love it when I make mistakes so you won’t be disappointed in this one, haha.

For the Sketchup File of the new revised top, click here. For a PDF version of the new top, click here.
And if you would like to donate to the cause, please check out the following links:
American Cancer Society
James Cancer Center

Steamer Trunk Plan and Hardware This plan shows you how to build your very own classic trunk… Steamer Trunk Plan and Hardware

Quick Links:
Steamer Trunk, Pt. 1
Steamer Trunk, Pt. 2
Steamer Trunk, Pt. 3
Steamer Trunk, Pt. 4