Coffee Table Tray

My husband and I moved to and incredible and romantic old farm in northern Minnesota, and we encouraged the previous owners to leave the contents of the barns and outbuildings as-is. One of the many antique treasures that I found was a perfectly adorable vintage wooden egg crate in the old coop storage. The wood was in relatively good condition and the writing on the slats were still quite clear so I was inspired to create a tray that would highlight the beauty of this charming piece of history.

Aside from the original crate, disassembled, I used a found piece of 1x3 wood that was charmingly worm-eaten, as well as a found piece of 1/2" plywood cut to square for the base of the tray.

other supplies used;

miter chop saw

finishing nails

small hammer

wood glue

matte clear top coat spray

Before handling vintage found items, be sure any dust and disinfect in an open area to prevent any contaminants from rodents etc. The slats of the crate are held together by a long metal pin, this can easily be bent and slid out of the slats.

Decide on the desired size of your tray. I let the size of the slats guide that choice and settled on a 16" square which would use all the beautiful slats, and be a nice size for a coffee table tray. Lay out the slats in a herringbone pattern with the flat edges down the middle. Depending on the condition of your crate, choose the nicest pieces for the center and the poorer edges for the runoff pieces! When I made my piece I marked the laid-out pattern and cut the pieces to size one-by-one prior to assembly. In hindsight, it may have been easier to assemble it all, then trim the lot as one cut. I was worried that the condition of the wood was too delicate and felt more comfortable with smaller safer cuts.

Cut the plywood to size, this will serve for a sturdy support for the tray itself, and a base to secure the slats. Arrange the precut slats on the base and secure them a thin strip of wood glue and a finishing nail in each end. Center the nail for aesthetic purposes. Continue until the pattern is complete and the base is covered.

Using the piece(s) of 1x3 wood, you will now be able to frame out the tray. Measure your base to be sure of the final size. I used mitered corners for a more polished finish, however a coped (staggered) edge will compliment the rugged look of the piece if miters are too daunting for you!

Make the bottom of the trim to be flush with the bottom of the tray. This will give you a flush base, as well as cover the rough edges of the base and the slats for a beautiful outer edge. Apply wood glue to the inner side of the board, and nail the strip along the bottom edge to the side of the base, and also on the corners using the finishing nails. Set the board aside for about 24hours to allow the glue to dry.

Now it is time to seal and finish the piece. Be sure to allow the glue to dry for at least 24 hours prior to this step. I chose a aerosol clear coat spray to seal the piece and help preserve the wood from further decay. I chose a matte finish so as to keep the natural vintage feel; a shiny finish seemed in-appropriate for such old wood, but of course that is to your taste when you get to this step!

Find a well ventilated room, or go outside for this part, fumes are inevitable. Spray the sealer in thin coats from a distance recommended by the manufacturer. Avoid trying to get it all in one coat or you are doomed to drips! In fact, it will likely take 3 or more coats as the old aged wood will be dry and soak up every drop of coating you spray.

Allow the piece to dry adequately before handling to avoid cloudiness or fingerprints. And allow the finish to fully cure before putting it into use. enjoy!