Follow Me Through a CRAZY Epoxy Dovetails in Curved Wood Tray Build

John Malecki

Follow Me Through a CRAZY Epoxy Dovetails in Curved Wood Tray Build

min read
Jun 19, 2020

The last time I made a box out of Epoxy and wood, you guys gave me some great input on making improvements for future projects. Many of you recommended that I try cutting the pins and dovetails out of actual epoxy instead of pouring it. So let’s give it a shot. 

Since I don’t believe in building things without a purpose, I decided to build a bacon tray that looks like bacon with epoxy. Because why the hell not? 


DIY Epoxy Dovetails in Curved Wood Tray Build: Overview

Fun DIY Wood & Epoxy Project for People Who Love Their Bacon

man in plaid shirt
  1. Break down the materials into strips
  2. Make the cauls
  3. Create bending template
  4. Glue up the boards
  5. Pour epoxy slides
  6. Cut the dovetails
  7. Transfer tails to Epoxy Pin Board and cut
  8. Assemble 

What You’ll Need



  • Slabs of Wood
  • Clear Epoxy
  • Nails
  • Tape
  • MDFs
  • Resin
  • Plastic 

DIY Epoxy Dovetails in Curved Wood Tray Build: The Step-by-Step

Break down the materials into strips

saw cutting through wood

In order to make the wood actually look like bacon, we’re going to do a bent lamination using cherry and maple, which means we need to cut up some thin slabs of wood first. So turn on your bandsaw so we can get started. 

Make the cauls

man in plaid shirt

Once you have all your slabs of wood, you’re going to make your calls. This is how you get all your thin strips of wood to curve just like a crisp piece of bacon. To make the calls, you need to laminated two pieces of MDF together before cutting them on the bandsaw. 

Create the bending template

person in woodworking shop

Create a grid pattern with lines on your slab of wood. This makes it easier to place the nails in a curved formation to make the piece bend. However, it can be difficult to bend the slab of wood when it isn’t steamed. If the bends are too curvy, the wood could snap. Once you figure out a proper formation, you’re going to want to mark it down with a pen before cutting the wood along your marking. 

Glue up the boards

person holding a piece of wood

As you can see, the boards are starting to look like a piece of bacon now that they’re glued together. But you aren’t finished yet. Once the pieces are finished drying, you’re going to want to smooth down the surface of the wood and make sure both sets of slabs are directly proportional to one another. If they aren’t, you will need to cut one of them down to give them the exact same measurements. 

Pour the Epoxy slides and cut the dovetails

person making a flow cast

Now, it’s time to pour your Epoxy slides and cut the dovetails. When the cast comes out, you mind find some nubbles on it. Smooth them out before cutting them up. Once you have two, flat squares of the cast, you can take a marking gauge and measure their thickness.  

Transfer tails to Epoxy Pin Board and cut

person carrying two pieces of wood

This step takes skill, precision, and a sharp saw. In order to piece together your two delicious slabs of wooden bacon, you need to make small cuts into each of their sides. Once you finish making those, you will need to make corresponding cuts into both of your flow casts that fit into the inserts on your bacon slices. 


wooden box

Once all of the pieces have been cut, it is time to put them together like a jigsaw puzzle. Hammer them in nice and tightly before sanding them down to keep their proportions even. Add a plastic bottom and sides to your masterpiece. Keep sanding them until their nice and smooth. When you’re done, give your bacon tray a little finishing spray for a final touch. 

Thanks for checking out this build! If you liked it, be sure to check out some of my other recent projects:

Download the Plan

Want to try this build out for yourself? Download the digital plan now for step-by-step instructions, measurements, and a detailed look at how to punch this project in the face.

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min read
Jun 19, 2020
Sponsored by
John Malecki

I used to be an offensive lineman in the NFL, Now I run my own furniture business and am completely self taught. In my videos and posts you'll see a variety of wood and metal work as well as some tips and tricks. Enjoy!