Millennium Falcon catch all tray

I'm rounding over the edges on this cherry Millennium Falcon catch all tray using a 1/4" roundover bit on the SawStop router table. It really cleans up the edge and gives it a much nicer feel.

Then I'm using the Surfprep 3"x4" ProFoam sanding pads to clean up all of the surfaces outside of the Falcon carving. I'll put finish on this next and then will be posting this and the other one out of spalted maple on my web site if anyone is interested. Would make great gifts for the Star Wars fan in your life.

#starwars #sawstop #surfprepsanding #sander #sanding

Waukee
2025/12/4 Edited to

... Read moreCreating a catch all tray like the Millennium Falcon design is a great woodworking project that blends creativity with functional craftsmanship. When rounding over edges with a 1/4" roundover bit on a router table, such as the SawStop, it’s important to maintain a steady feed rate to avoid burning or tear-out, resulting in smooth, safe edges that feel pleasant to the touch. After shaping, sanding plays a crucial role in achieving a refined finish. Using high-quality sanding pads—like the 3"x4" Surfprep ProFoam pads mentioned—ensures consistent surface preparation. These flexible foam pads adapt well to the contours around the carved Falcon shape, helping to remove any tool marks and prepare the wood for finishing. Choosing the right finish enhances both the appearance and durability of the tray. Options such as natural oils, varnishes, or polyurethane provide protection while highlighting the rich grain of cherry wood or the unique patterns in spalted maple. For Star Wars enthusiasts, this personalized handmade item makes a thoughtful, stylish gift that adds a touch of fandom flair to any room. Additionally, when working on such detailed pieces, it helps to periodically wipe away dust between sanding grits and test finishes on scrap pieces to ensure the desired color and sheen. Sharing this process through a blog or video can inspire other makers in the woodworking community and provide valuable tips for similar projects. Ultimately, combining precision tools, quality materials, and careful finishing techniques results in a stunning Millennium Falcon catch all tray that any collector or fan would cherish.

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