Behind the Build: A Real Custom Project from Sketch to Shipment

When people hear “custom woodworking,” they often imagine a simple change in size or colour. In reality, custom work is a collaborative process that blends design, problem-solving, craftsmanship, and communication. The best way to explain how we work is to walk you through a real project from start to finish.

The Client’s Idea for the Custom Project

This custom project started when a client contacted us with a photo of three round metal canisters she already owned. Her goal was to turn them into functional side tables by adding hardwood tops with surrounding sides.

She provided the key measurements right away:

• 10-inch diameter

• 12-inch diameter

• 14-inch diameter

Because the client was located hundreds of kilometres away, accuracy and built-in tolerance were critical from the start.

The first thing we do is provide a mock-up of the idea if there is not a picture provided and provide the measurements back to the client.

The Tops of the Canisters

Choosing the Right Wood

We discussed several hardwood options, balancing appearance, durability, and cost. While the client initially considered thicker, 3-inch sides, we walked through why that would be both expensive and visually overbuilt for the scale of the canisters.

After reviewing pption and pricing, she chose Ash:

• Strong and durable

• Clean, modern grain

• Cost-effective compared to some other hardwoods such as Maple and Oak.
  

A 2-inch side height provided the right balance of strength, appearance, and practicality.

Designing for Real-World Variations

One challenge with custom projects—especially remote ones—is accounting for variables you can’t measure in person. The canisters themselves had decorative raised details along the sides, which meant a tight fit could cause issues.

To ensure the tops would sit properly, we:

• Added 7/8 inch of extra clearance around each top

• Designed the tops to rest securely without binding

This extra space allows the tops to sit cleanly while still looking intentional and well-fitted.

Canister Top with sides

The Build: Where Custom Gets Interesting

We cut circular pieces regularly, but this project added complexity. These weren’t just flat tops—they were circle tops with 2-inch hardwood sides, meaning the grain direction mattered.

Cutting the Tops

• Used a circle jig to cut the tops

• Each top was ¾ inch thick, which was straightforward and clean
  

Building the Sides

This is where things became more complex:

• The sides included ½ end grain and ½ long grain around the perimeter

• After gluing up the hardwood, we trimmed excess material

• A 2-inch router bit was used to shape the outer edge—this worked perfectly

The inside edge, however, presented a challenge.

Adjusting the Process

Ash is a hardwood, and routing 2 inches deep straight down was simply too aggressive for the setup. Rather than force the tool (and risk tear-out or damage), we adjusted:

• Cut the centre opening on the bandsaw

• Refined the shape using an oscillating sander

• Glued the sides to the top and clamped for 24 hours
  

For added strength, we:

• Drilled ¼-inch dowels into each side, tying the sides into the top
  

This extra reinforcement ensures long-term durability.

Unfinished Side of Canister with Dowel

Sanding: Where the Time Really Goes

Sanding is often the most time-consuming part of a project—especially with mixed grain directions.

• Progressed from 120 grit to 240 grit

• Paid extra attention to end grain, which naturally absorbs more and feels rougher

• The goal: make the end grain feel as smooth as the long grain

This step is critical for both comfort and finish quality.

Stain and Finish Selection

Before committing to a final finish, we tested several stain options in tones the client liked. She ultimately chose Aged Barrel by Varathane, a rich brown with subtle grey undertones.

Why Varathane?

• Excellent coverage

• Consistent results

• More nuanced colour options than many traditional stains
  

Finishing Process

• Applied pre-stain conditioner

• Applied stain and allowed it to cure for 24 hours

• Finished with satin Varathane (the client preferred no gloss)

• Applied three coats, lightly sanding at coat two with 240 grit

• Allowed 24 hours of drying time per coat
  

  

  Finished Canister Lids

  
  

Final Steps: Packing and Shipping

Once complete, we:

• Carefully packed all three tops and they fit in an 18x18 x 12 inch box

• Weighed the shipment

• Used ClickShip to determine the best carrier and shipping method for the client location as not all carriers travel to remote areas.
  

This ensures fair, accurate shipping costs based on the client’s location—not inflated or embedded pricing.

Packed for Shipping

Why We Love Custom Work

Every custom project teaches us something new. This one involved design tweaks, tool limitations, problem-solving, and extra planning—but that’s exactly what makes custom work rewarding.

From a simple photo to a finished hardwood piece, this project is a perfect example of how collaboration and craftsmanship come together.

If you have an idea—whether it’s fully formed or just a starting point—we’re always happy to talk through the possibilities.

Fill in our Custom Form and we can start the process.