Pinecone and Epoxy Coaster Set

Level of Difficulty: medium

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Select and prepare a piece of live edge wood by cutting to dimensions roughly measuring 17 in. length x 1-3 in. width x 1 in. height, curly maple was chosen for this project. (Note: When cutting to proper width, leave live edge.)
Use a jointer to flatten bottom and the non live edge length side perpendicular. (Pic 1A)
Use a miter saw to trim each end to an overall length of 17 in. (Pic 1B)
Clean up and remove bark and debris from live edge using a combination of a draw knife, power sander, and hand sanding. (Pic 1C)
It is not important to plane the top side at this time, however sand using 80 grit to prevent debris from falling into epoxy. (Pic 1D)

Cut one piece of 1/2 in. or 3/4 in. plywood 19 in. length x 6 in. width for the bottom piece.
Cut two pieces of plywood measuring 18 1/2 in. length x 2 in. width for longer sides. (Pic. 2A)
Cut two pieces of plywood 4 1/2 in. length x 2 in. width for ends. (Pic. 2B)
Cover all pieces in epoxy or sheathing tape. (Piece 2C)
Using construction screws, fasten together pieces to create the mold box with inside dimensions measuring 17 in. length x 4 1/2 in. width. (Tip: Utilize clamps to hold sides to bottom piece in place and screw together from underside.) (Pic. 2D)
Seal all inside seams using hot glue or caulk. (Pic. 2E)
Hot glue or caulk live edge wood into place with live edge running down the length of the middle. (Pic. 2F)

Mock up assorted pinecones into positions opposite the live edge wood for pouring the epoxy. (Pic. 3A) (Tip: Take picture of cones when placed to help reposition into epoxy.)
Calculate amount of epoxy needed for the first and second pours, using an online epoxy calculator. First pour measures 17 in. length x width (live edge to the side) x 1/8 in. depth. Second pour being same length x width x 7/8 in. depth. (Pic 3B)
For this particular project the first pour calculates to 3 oz. and 24 oz. for second pour.

Determine which color(s) you would like for the coaster set or prefer clear epoxy, for this set two parts Mixol #25 Oxyd White pigment combined with one parts Eye Candy 14k Nugget Gold Mica powder was chosen. (Pic. 4A)
Mix first pour of thin pour table top epoxy, following manufacturers instructions. (Pic 4B)
Separate epoxy into two cups at a two to one ratio. For this project 2 oz. in one cup and 1 oz. in second cup. (Pic. 4C)
Mix Oxyd White into 2 oz. cup and 14k Gold into 1 oz. cup and then pour into mold. (Pic. 4D) (Tip: Pour white first and wait until epoxy thickens and then pour gold and swirl together.) (Pic. 4E)
Use heat gun or torch to release bubbles before epoxy cures, being careful to not burn or over heat.
Before epoxy hardens place pinecones into mocked up positions. (Pic. 4F)
Cover mold and let sit until epoxy cures.

Mix second amount of Deep Pour Epoxy, following manufacturers instructions. 24 oz. for this project. (Pic 5A)
Separate into two cups at a 2 to 1 ratio. 16 oz. in one cup and 8 oz. in second cup. (Pic. 5B)
Add Oxyd White to 16 oz. cup and 14k Gold to 8 oz. cup. (Pic. 5C)
Pour white into mold, being sure to coat pinecones. (Pic. 5D)
Use heat gun or torch to eliminate bubbles and then wait for epoxy to thicken.
Pour 14k Gold into mold and mix with white until desired opaqueness is reached. (Pic. 5E)
Eliminate bubbles with heat gun or torch occasionally until epoxy becomes tacky.
Cover and let sit until epoxy full cures, generally 2 to 3 days.

Deconstruct sides from mold and remove coaster set from mold base. (Tip: A rubber mallet and flat bar will help pry loose from the mold.) (Pic. 6A)
Standing coaster set blank on the side, trim excess pinecones outside of epoxy using the bandsaw. (Pic. 6B)
Flatten bottom of coaster blank and one side perpendicular using jointer or securing to a planer sled and flatten the top side. (Pic 6C)
Once one side is flattened, plane opposite side to the desired uniform thickness, 1/2 in was chosen for this blank. (Pic. 6D)
Using the table saw, trim the the blank’s width to 4 in. (Pic 6E)
Trim one end at 90 degrees using miter saw or a miter gauge on the table saw. (Pic. 6F)
Set miter gauge stop block to 4 in. and cut the four coasters from the trimmed end, leaving you with a set of four, 4 in. x 4 in. coasters. (Pic. 6G)

Secure Milescraft sub compact base to trim router to provide a stable platform and secure router upside down in bench vice. (Pic 7A)
Using an 1/8 in. round over bit in a trim router, profile each coaster’s edges. (Pic. 7B) (Note: If a different edge profile or none is preferred, edge to preference.)

Clean out small gaps and holes exposed while cutting to size. (Pic 8A)
Using clear CA Glue, fill all imperfections on all sides of coasters. (Pic 8B) (Tip: Use accelerator to cure quickly.)
After CA Glue cures, sand each coaster through grits 80/150/220/320. (Pic 8C)

Wipe down and clean coasters free of dust.
Prop coasters up with milescraft tri grips and apply preferred finish to coasters, for this set Atomic Finishes Universal Oil was chosen. (Pic 9A)
Buff and polish finish once fully absorbed and allow time to cure.
Once dried coasters are ready for use, sit back and enjoy your creation. (Pic 9B)

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