Expert: Jamie Yocono - 1/25/2009

Question
I'm winding down a desk project that I've built for myself.  The desk is two European style cabinet boxes with a plywood panel that spans between them to create the sitting area.  The boxes, drawers & fronts are complete & finished and I'm now on to creating a top for my new desk.  Originally, I had planned to purchase a piece of granite for the desktop as I love the look of stone.  More recently, I've reconsidered that cost and am now entertaining a matching red oak plywood top with a decorative edge.  Here's when I get stumped.  Can you recommend how best to add a hardwood "frame" to the perimeter of the plywood to add some dimension to the top?  I'd also like to have enough material (~ 1") thickness to add a profile to the desktop edge.  Any images or references that you could provide would be helpful.

Thanks,

Todd

Answer
Todd,

The best way to add edging to a plywood panel, to conceal the ply edges, is probably to wrap the whole perimeter of the plywood with solid wood edging. Plywood is dimensionally stable, meaning it's not going to shrink or swell with seasonal humidity. So once you edge the panel, the corner joints you create will stay closed.

Most woodworkers would use 3/4" plywood for that top, and then apply an edge of wood, say 1x2 vertically, so that the 2" (1.5" actually) is facing out. Orienting the wood this way also provides you with some strength, keeping the plywood from sagging or flexing under the load. You could biscuit the 1x2 to the plywood, to keep if from moving around while you're gluing it.

You can choose which joint you would like at the corners -miters look nice but are harder to do than simple butt joints. If you use a butt, I suggest edging the sides first, making sure that the edge is exactly flush with the plywood end. You can trim the sold wood edging with a saw or flush trim router bit, or even sand it flush with a belt sander. Then apply the edging to the front and back of the desk. That way you won't see any end grain from the front or back.

One last thing - I would build up the thickness of the plywood all the way around perimeter of it, so that when you attach that solid wood edging, it's completely backed by wood. That means - if your top is 3/4" and you would like it to appear that it's 1 1/4" thick, you could add a layer of 1/2" wood all the way around the edges of the plywood, say 2 or 3" wide. You scan screw it in place, or glue it, it doesn't matter. Make this layer out of plywood or solid wood, doesn't really matter, either. Then - looking at the edge of the raw material, it would have that 1 1/4" thickness all the way around the edge, perfect for applying solid wood. It's a very professional way of making a top.

Look at this web page, and scroll down to the last image (#6) and you'll see what I mean about adding a piece of wood.
(http://daveosborne.com/dave/articles/countertops.php) This diagram shows only a narrow piece of wood, but I like to make it much wider, like 2-3" wide. That way, when you look from the bottom of your desk, you really don't see anything added, as the lower cabinets conceal this layer.

One last thing - have you ever considered making a concrete desk top? If you were considering using granite, but had to change your mind because of the cost, concrete might be an interesting alternative. I just bought this book, it might give you a few ideas:

http://www.amazon.com/Concrete-Countertops-Design-Finishes-Kitchen/dp/1561584843

OK, I think I've answered your question, but feel free to write back if you have more. Good luck.

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com