Step 1: Cut the butcher block.

cutting the butcher-block with a circular saw
Photo: Ryan Benyi
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Start with the countertop facedown. Measure and mark the piece with cutlines for the countertop and lower counter. Clamp a straightedge adjacent to the first line as a saw guide. Keep the clamps out of the saw's path. Apply tape over the line to minimize tear-out. Use a new 40-tooth carbide-tipped blade, and adjust its depth to ¼ inch more than the thickness of the wood. Make your first cut. Reclamp the straightedge, tape the second line, and make the cut.
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    Tools List

    • 30-foot tape measure
      measuring tape
    • hand clamps
      clamps
    • straightedge guide
      straightedge
    • Painter's Tape
      painter's tape
    • circular saw
      circular saw
    • random orbit sander
      random-orbit sander with 100-, 120-, and 180-grit discs
    • drill
      drill/driver
    • Lag-screw driver bit
      driver bit
    • belt
      belt
    • Rafter Square
      rafter square
    • 1/8-inch bit with combination countersink
      -inch bit with countersink
    • combination square
      combination square

    Shopping List

    Butcher-block countertop.
    Get one 25-by-96-inch piece IKEA.
    (Note: The size of the gas pipe has been corrected from the print edition.)

    ½-inch iron threaded pipe.
    Get one 36-incher, six 18-inchers, two 12-inchers, four 6-inchers, six 5-inchers, two 4½-inchers, and six 2-inchers.

    ½-inch iron threaded pipe elbows. Get two.

    ½-inch iron threaded pipe flanges. Get eight.

    ½-inch iron threaded pipe tees. Get 14.

    1x10 oak board. Get one 8-footer.

    Wood glue

    1-inch No. 10 flat-head wood screws for securing the flanges and shelf boards casters. Get four.

    1-inch No. 10 pan-head wood screws for securing the casters

    Beeswax

    Mineral oil