Making the BBQ Block involves a sequence of steps that go from a rough air-dried plank to a finished serving board. Each step involves a decision, not just an action. Here’s the process as it actually runs.
From Plank to Board
Step one is plank selection and assessment — covered separately in our sourcing post, but critical to what follows. Only planks that pass the grain, crack, and character assessment move forward.
Step two is rough cutting to board dimensions. The plank is cut to the target length and width, leaving margins for the finishing work. The live edge is retained on one long side — this is non-negotiable in the design brief. The opposite edge is cut straight to give the board a stable reference face for use.
Step three is planing flat. The working surface of the board needs to be level — flat enough that a piece of meat or a carving knife sits without rocking. Handplaning achieves this while respecting the grain direction. The live edge remains untouched throughout this stage.
Step four is sanding through grits. We run through 80, 120, 180, and 240 grit in sequence. Each grade removes the marks left by the previous one and reduces surface roughness further. By 240 grit, the surface is smooth under a bare hand — that tactile quality is part of what makes the finished board feel right. Skipping grits produces a surface that looks smooth but feels wrong. We don’t skip.
The Finish
Step five is the food-safe oil finish. We use a food-grade oil — linseed or beeswax-based — that is safe for direct food contact. This matters for a serving and carving surface that will have raw and cooked food placed directly on it. The oil goes on in multiple coats, each absorbed into the grain, building a finish that protects the wood and feeds it. The first coat raises the grain slightly; a light sand between first and second coat addresses this. The final coat is buffed.
The oil finish also brings out the character of the oak — the colour deepens, the grain becomes more defined, the live edge takes on a richness that the unsanded plank doesn’t show. This is the moment the board becomes what it is.
Signing and Shipping
Step six: each board is signed before it ships. A person made this specific board. We want the person who receives it to know that. The signature is not decorative. It’s a record of accountability — this board was made by a named maker who put their name to it.
Because every oak plank is different, every BBQ Block is genuinely unique. The live edge, the grain pattern, the exact dimensions — no two are identical. That uniqueness is not a production inconsistency to manage around. It’s the product.
