DIY Torched Epoxy Table | Shou Sugi Ban

 

This project is a Shou Sugi Ban table, taken a little farther by adding an epoxy resin tabletop. It starts with building a simple side table and can be elevated with the steps below. All you need is a few boards of new wood or scrap wood.

Steps

Step 1

The first step is to get the plywood cut. You should start there in order to ensure the base is flush with the top. Build the top first, double check your measurements and then cut the base pieces.

Tape measure
 
Use 1 1/4” 18 GA brad nails and wood glue to attach the trim to the plywood top piece. Be sure to use wood glue for this step and spread it out over the edges of the plywood, because it will help a create a seal so the epoxy won’t leak later in the project. Also, the lip that this creates will give you a nice mess free surface when pouring the epoxy.

Air stapler

Board

Clamps

Step 2

Remeasure to make sure your base measurements will work with your finished top. Cut your pieces to size and drill 1 1/2” pocket holes on each end of the bases pieces (not the legs). Then assemble using 2 1/2” pocket hole screws and wood glue.

Table legs

Pocket holes

Frame
 
Use the blue coated pocket hole screws because they are rated for outdoors and that is where the table will be. Also, note that you should face the pocket holes either up or down during assembly so that when the table is upright you won’t see any pocket holes.

Pocket hole screws

Step 3

Attach base to top using 2” wood screws. Would recommend using exterior rated ones for the table if you are going to have it outside.

Top clamped

Once the base is assembled, lightly sand it and get rid of any sharp corners.

Step 4

Shou Sugi Ban the base using the Bernzomatic 8250HT.

Torch

Torching partially complete

Torched frame

Step 5

For the epoxy top, start by taping off the top trim edges because you don’t want to accidentally drip epoxy on them. Then mix up the epoxy to cover the base and to mix with the colors. Make sure that the base is level so that the epoxy would also be level.

Masking tape

Epoxy mix

Level
 
Steps for the epoxy pour:

  • Have your base painted a color that you don’t mind showing through.
  • Pour a base layer of clear epoxy and spread evenly to the corners. Having this base layer will allow the colors you add to flow and mix better.
  • Pop all the air bubbles with a Bernzomatic ST2200T torch.
  • Pour a color or two randomly on the table and use a hair dryer on hot and high to move the epoxy. Be sure to move it in all different directions to not get thin spots in the epoxy.
  • Repeat until you get desired look.
  • In spots where the colors aren’t mixing, add clear epoxy, which helps break up colors and add depth.  
  • Let it cure overnight and add a top coat of clear epoxy the next day. Do this so that if the top gets scratched down the road, it won’t affect the color design. Remember to pop the bubbles using the torch after every pour to get a nice glassy finish!

Epoxy top

Step 6

Add a coat of clear epoxy on the base. You can also add a coat of oil to finish it so that none of the char comes off.

Clear epoxy

Table on porch

Colored epoxy

Complete torched table

What You'll Need


ST2200T
ST2200T

Detail Torch for Hobby and Household Use

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BZ8250HT
BZ8250HT

Hose Torch for Accessibility and Mobility

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BF55
BF55

5.5 oz. Butane Cylinder

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TX9
TX9

14.1 oz. Propane Hand Torch Cylinder

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Materials

  • 2 – 2x2x96 Pine Boards
  • 1 – 1x2x96 Pine Board
  • 1—Scrap ¾” Plywood 15 ¼” x 15 ¼”
  • 7—Base Pieces: 1 ½” x 1 ½” x 13 ¾”
  • 4 – Legs 1 ½” x 1 ½” x17”
  • 2—Top Trim: ¾” x 1 ½” 15 ¼”
  • 2—Top Trim: ¾” x 1 ½” 16 ¾”
  • 1—Top: ¾” x 15 ¼” x 15 ¼”
  • Epoxy
  • Wood glue

Tools

  • Miter Saw
  • Drill
  • 18ga Brad Nailer with 1 ¼” nails (optional, could use hammer and nails instead)
  • Pocket Hole Jig with 2 ½” PH Screws
  • Table Saw (optional, can have store cut)
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