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Here is how I make a glue-up panel. If you're like me, a "thrifty" woodworker, and don't have a fancy planer and/or a jointer, that's okay. You can still make a nice glue-up panel for your next project. All you need is a table saw, some clamps, and an orbital sander. I built this glue-up top for a drill press stand using some left over 2×8's from another project. Yes, it would have been easier and quicker to use plywood, but doing a glue-up is pretty easy and, in my case, it saved a little money too. Plus, glue-ups look great!!

For Step by Step Directions: http://brattonbuilt.com

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HERE'S WHAT YOU NEED TO MAKE A GLUE-UP PANEL.

LUMBER CUTS USED:
(4) 19″ 2×8's

TOOLS USED:
Table Saw (With sled, but not needed)
(3) 36″ clamps
(6) Smaller clamps (at least 6″ clamps)
Orbital Sander (60 grit, 80 grit, and 120 grit sandpaper). Note: I would use 220 grit if this glue-up was for furniture.
Paint Scraper
Optional: Table Saw Finger Board

SUPPLIES USED:
(4) Cauls (1×3 boards wrapped in packing tape)
Plastic cover that's a little bigger than your glue-up.
Wood glue

STEP BY STEP DIRECTIONS ON HOW I DO GLUE-UP PANELS USING A TABLE SAW
STEP 1: MAKE THE CUTS

Start by cutting your boards at least one inch bigger than you need. For this project I wanted an 18″ wide panel so I cut them to 19″. (By cutting them a little big you'll be able to cut them perfectly smooth after glueing.)

STEP 2: RIP FOR SMOOTH EDGES

Rip both edges of your boards to the desired width. This rip is to create nice clean edges for the glue to adhere to. Again, it's a good idea to cut them a little big and then trim your glue-up down to size latter. Note: I like to use the miter finger board, but it's not necessary for this cut.

STEP 3: SET UP CLAMPS

Put some plastic on top of your work surface and lay down a couple clamps. I used a two scrap pieces to prevent the clamps from digging into the wood. Then line up your boards how you want them. If your panel is for a piece of furniture you will want to play around with getting the patterns lined up so it looks good.

STEP 4: GLUE BOARDS

Add glue to one side of each joint. It should be nice and thick so you can't see the wood. Then line your boards up.

STEP 6: ADD CAULS

Add the cauls to the top and bottom of each side and lightly clamp over each joint. (Cauls help to line up any wonky boards)

STEP 7: ADD TOP CLAMP

Add another long clamp over the top. (This is because clamps exert more pressure on the bottom.). Now your ready to evenly cinch all your clamps down a little at a time.

STEP 8: SCRAPE GLUE

After letting the glue dry overnight scrape off the glue with a paint scraper.

STEP 9: SAND

Sand off any remaining glue and level it out. For this panel I used a 60 grit, then an 80 grit, and finally a 120 grit sand paper. I would use up to a 220 grit sandpaper if this panel was for furniture.

STEP 10: FINISH

Finally finish your glue-up panel with a lacquer, polyurethane, tung oil, or whatever you prefer. I like to use spray lacquer for small projects because it's just so easy and quick. I chose to keep this top it's natural color, but you may want to add a stain before finishing.

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Check out furniture projects that use glue-up panels!
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