As a reminder, I recently built a sales counter for a friend that is roughly 14 feet long. It has been installed, and the last thing left to do was join two store-bought butcher block counter tops together into a single long slab for the top.
Easy, right? Well, kind of. I'm going to get a lot of practice. I made it too long the first time, so I get to try again.
Here's how I did it the first time. With a series of too-complicated router setups, I created a half-lap joint between the two top slabs. This turned out to be ultra-strong, but was the source of my error. Somehow I messed up and the length of the overlap was added to the total counter. The half-lap is about 3 inches wide.
|Half lap joint is very strong, but I didn't measure correctly for overall length.|
This sales counter has a jewelry case at each end, so part of the design called for a glass insert in each end of the top. You can see one of the cutouts in the picture below, and there is one on the other end too.
|After adding cutouts for glass inserts, the only option is to cut it back apart to fix the length.|
The other challenge is that the top has been stained and I have several coats of durable poly applied as a finish. I really don't want to repeat the half lap process, because I don't want to have to sand or plane the joint to get it flush. I haven't had good luck touching up a stain/poly finish and I don't want to strip the entire top.
I'll keep you posted. Back to the shop.
Ever have one of those days? Got any ideas? How would you recover from this blunder? I'd love to hear it!