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I Build a Massive Epoxy-Inset Live Edge Conference Table

John Malecki

I Build a Massive Epoxy-Inset Live Edge Conference Table

I Build a Massive Epoxy-Inset Live Edge Conference Table

Projects
|
6
min read
|
Aug 9, 2019

I recently reached out the the guys at Black Rifle Coffee Company - a veteran-owned and operated coffee company based out of Salt Lake City - about partnering with them on a project. In perfect timing, BRCC had recently moved to a new office in Texas and was need of some new furniture. After a conversation of epic proportions, we decided on a massive epoxy logo-inset live edge conference table that is easily one of my favorite projects I’ve ever completed.

This project turned out to be more than 20 feet long and so big I had to assemble it on-site. Sourced with sustainably-harvested slabs and a custom-made center emblem, this was no easy task but I’m super proud of the work I had an opportunity to do for such a great company. So check it out -- click below for the video on how I build this absolutely insane live edge conference table!

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Project Overview:

How to Build an Epoxy-Inset Live Edge Conference Table

  1. Pick Your Slabs
  2. Cut Medal for 4 Pedestals
  3. Build Up Pedestals
  4. Create Epoxy Inset
  5. Sand Live Edge
  6. Cut C-Channels on the Slabs
  7. Spray Finish & Final Build-Up

What You’ll Need for an Epoxy-Inset Live Edge Conference Table

Materials

  • Metal Tubing for Pedestals
  • 2 Live Edge Slabs
  • Brass Bullet Casings
  • Epoxy

Tools

How to Build an Epoxy-Inset Live Edge Conference Table: The Step-by-Step

Pick Your Slabs

BRCC wanted something BIG for this project, so I went to Woodcraft and picked out two slabs, each about 14-15 feet long. I went with a Guanacaste slab from South America because it was important for Black Rifle to use a piece of wood that was sustainably harvested, and this wood brought a really sweet look to this project. Let your wood acclimatize in your workshop for about a week.

Cut & Build 4 Pedestals

The live edge conference table was designed to be supported by four pedestals designed to looks like the Vulcan Turret Black Rifle. I accomplished this by creating 8-spoke pedestals and numerous 6-inch sleeves to go over the spokes, placing flat metal disks between each sleeve. I welded this together and cleaned up the top and bottom welds with an angle grinder for a flat finish.

Create Epoxy Inset

Joining the two slabs is a massive epoxy inset of their logo filled with .223 brass bullet casings. This part of the project took quite some time, which is why I created a separate video and blog post for it.

In summary, you’ll build and route out a wooden frame for the mold with a homemade jig. Seal the mold and route out the logo with a CNC. Once the wood details are placed in the inset, pour the bullet casings and mix your epoxy. When the epoxy is fully set, sand and finish the inset until crystal clear and smooth.

Cut & Sand Live Edge

While the epoxy inset is setting, use the same jig setup to cut the hole in the live edge slabs for the inset. Double-check your measurements first.

Next, you’ll want to sand your live edge. Start by removing the bark. The bark is already dead and is going to fall off eventually, so I recommend speeding up the process and doing it yourself. Sand the whole thing down until smooth.

Cut C-Channels on the Slabs

Because wood can expand in different climates, be sure to cut and add metal c-channels with countersunk screws to allow for expansion and contraction without bringing to question the structural integrity of the table.

Spray Finish & Final Build-Up

Once sanded, I spray finished the wooden slabs and packed everything up for transport. This thing is obviously huge, so I saved build-up for when I arrived at their office. I carefully slid the inset in between the two slabs and voila -- one hell of a live edge conference table.


If you want to see more builds like this, check out these 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.

Projects
|
6
min read
|
Aug 9, 2019
|
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!