How to Build Wooden Quilts

Select a quilt block pattern. Choose enough different hardwood species to represent each separate color called for in the quilt block design. Slice 1/8-inch-thick veneers from the hardwoods with a fine-tooth blade on a band saw. Set the fence on the saw 1/8 inch from the blade to make consistent cuts. Cut enough of each wood to fill the space you intend to fill with that grain pattern.

Print a copy of the quilt block at full scale. Cut the pieces from the copy with scissors and use spray glue to attach each piece to the wood grain you choose for that piece. Cut along the edges of the paper pattern as closely as possible. Sand the edges to correct any minor irregularities. Paint pieces with semigloss latex paint and an art brush if you intend to make a colored design. Allow the paint to dry thoroughly.

Cut a piece of 3/4-inch-thick cabinet-grade plywood the size of the quilt block. A typical quilt square is 12 inches across. Cut a second square 2 inches larger than the first. Cut four strips of 3/4-inch-thick hardwood 7/8-inch wide and 1 1/2 inches longer than the edges of the smaller plywood square. Miter each end at 45 degrees so that the short face of the mitered strip fits the edge of the smaller plywood square.

Glue and nail the strips to the edges of the square with one long edge of each strip flush with the bottom of the square so that the top edge extends 1/8 inch above the top face of the square to provide a frame for the quilt block pieces.

Peel the paper from the quilt block pieces and spread wood glue on the back of each piece with a small art brush. Fit the pieces together inside the frame, aligned to match the quilt block pattern. Place a sheet of wax paper over the face of the quilt block and place the larger plywood square on top of it. Clamp the top block to the quilt block with one C-clamp at each corner and allow the block to set overnight.

Remove the clamps and sand the face of the quilt block with a random orbit sander and 150-grit sandpaper. Fill any gaps between the pieces with a flexible putty knife and solvent-based wood filler. Allow the filler to harden and sand the face with 200-grit sandpaper to finish.

Apply two coats of clear finish with a fine bristle brush. Make all strokes in one direction, spreading the finish as evenly as possible to prevent runs and drips. Allow the label-recommended time between coats.