Live Edge Star Wars Desk

A long time ago in an office far far away...

A desk was needed, so let's make one!

Here's what I used to build this desk. This is the way

Materials I used: (with affiliate links)

Sycamore slab - Find a local dealer for best options for this

Bloodwood - https://amzn.to/34esql5

Katalox - https://amzn.to/3Gsq3rQ

Epoxy resin - https://amzn.to/3IYbKgj

LED strip - https://amzn.to/3ollcm7

Arduino - https://amzn.to/3ukFq34

Battery pack - https://amzn.to/3uqJHCb

Wireless charger - https://amzn.to/3sh4ohr

Tools I used:

Hand rasps - https://amzn.to/35PGYrX

Chisels - https://amzn.to/3glSmxq

Draw knife - https://amzn.to/3Hw54pC

Scroll saw - https://amzn.to/3GsqDWy

Band saw - https://amzn.to/3s6aKji

Router - https://amzn.to/3L2e4Vs

Hand router - https://amzn.to/3ollMAj

Router bits - https://amzn.to/3IWj9Na

To start out, you need to clean the crack. Don't laugh.

Using some hand rasps and some chisels, I took all the rough edges and splinters out of the cracks and splits on both sides of the slab. Starting with the rough grit and moving to a finer grit, I started to shape the cracks to allow for a cleaner pour when it came time to do the epoxy.

Using the chisels, I took off sections that were too split to fix, or cleaned up the edges to prevent further cracking or splitting later.

Using a draw knife I took the bark off of both sides of the slab. Some people choose to keep the bark on a slab, so this part is a personal preference. To prevent the bark from rotting and falling off, it would need to be sealed with epoxy, which would take time to get all the uneven edges of the bark. To avoid this I opted to just remove the bark from the edges.

To make the inlays for the table I decided to use a piece of 1/4" bloodwood for the rebel symbol, and some katalox for the tie fighters and millennium falcon.

For the rebel symbol I printed off and cut out a stencil, then traced it onto the bloodwood. I took the piece to a scroll saw and cut the shape out, then smoothed out some of the rough portions with a micro sander.

Since the katalox is so dark and dense, trying to trace on it didn't work. Instead, I used the laser cutter to engrave the outlines of the tie fighters and millennium falcon, then took the pieces to a bandsaw to cut out. I cleaned up the edges with a belt sander, and they were ready.

I started by laying down some painters tape over the areas where I was going to be putting the inlay pieces. Using the figures I cut out, I traced the outlines onto the tape. I took a knife and cut the outlines of each shape, then removed the inside of the tape.

Rather than tracing the outlines directly onto the wood and cutting it out, I did it with painters tape to give a clearer and more noticeable line (especially when running the router), and help with any chipping that might occur at the edges.

Using a chisel I cleaned up the edges of the mortises. I added glue to each mortise, then used a rubber mallet to gently tap the ships into place.

SIDE NOTE: Although katalox is a very hard wood, it splits VERY easily. Please be careful and patient when tapping the pieces into place, otherwise they will break.

After each piece was in place and dry, I took an orbital sander and evened it all out.

Trying to do my best Kylo Ren impression, I grabbed some roofing tape and taped the bottom of the slab. I flipped the slab over and taped up the end of the crack.

Measuring out enough epoxy to fill the crack and smaller knots in the slab, I mixed both parts together and then stirred, and stirred, and stirred some more. Once it was sufficiently stirred, I poured the epoxy into the crack and other split and knot areas on the face of the slab.

Using a blowtorch, I popped any bubbles that came to the surface, then let it all sit and cure.

After it was cured, I removed the tape, then used a card scraper to even the epoxy down.

This can also be accomplished with a sander, or planer, but I chose to use a card scraper.

I wanted to have a wireless charger built into the desk that sat just below the rebel symbol, so I picked up a charger and set it on the bottom side of the desk above the rebel symbol. I traced the outline of the charger, and marked a line for the power cable, then used the router to route out the area for the charger and cable.

SIDE NOTE: In order for the charger to work, it needs to be JUST below the surface of the desk, which means routing out a majority of space below the symbol. This means being VERY careful not to cut all the way through the desk. So keep that in mind - and carve slowly.

Wanting a sturdy pair of legs for this hefty slab to sit on, I asked a friend to weld up custom legs for my desk. The legs were designed with several mounting points, so once I received the legs I set them on the bottom side of the desk and marked out my mounting locations, then pre-drilled each hole. Using a bolt and a washer, I secured the legs to each side of the desk.

I wanted to add a light effect to the bottom of the desk to shine through the crack in the desk, that made it look like the Millennium Falcon (which was at the beginning of the crack) was shooting at the tie fighters (both of which lay further down the crack). To accomplish this I enlisted the help of Wes from Geeksmithing, who took an arduino and added some simple code to randomize the length and frequency of the LEDs lighting up from the start of the strip to the end. Adding a battery pack to it, I secured the battery pack, arduino, and neopixel strip to the bottom of the desk, and used hot glue to secure all the wiring in place.

With everything done, it was time to add finish. You can use your favorite finish of choice - my choice was to make my own. Mixing equal parts linseed oil, mineral spirits, and polyeurethane, I combined them in a container, shook it like a poloroid picture, and added the finish to the desk.

Now the desk is done! Now you can sit and write about galaxies far far away, or put a TV on it and watch your favorite Star Wars film, or setup your computer on it and play some Rebel Assult. The choice is yours, but whatever you choose to do you can now do on an incredibly Star Warsy desk!

Now that you've seen how it's made, watch the video!

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AND you can watch more of my project videos HERE

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