A piece of “scrap” butcher block from this project Day 900: Floating Desk piqued Eric’s interest: could it be used on our Weber Performer? A quick fit says it was meant to do exactly that!
The second step was to remove and clean the cutting board from the grill, and clamp the butcher block to radius the ends with a flush cut router bit.
Multiple attempts at clamping were needed to find one that allowed the router to fit all of the way around.
The head of this didn’t need that much material removal.
Part way through the cut, the bit needed to cool off.
Eric experienced multiple failures on the back end, the first being this separation of block by the router. This was easily glued with no discernible visual effect.
The second was a little more serious: the router bearing came apart, which allowed the bit to wander into both materials.
The only part that was recovered. A new bit was swapped out under warranty, since a similar bearing was not on hand.
Luckily damage was minimal, and it is mostly concealed by the grill body itself.
New bit arrived, and it was time to get back at it! After a number of grits sanding the surface and all radiused edges, it was time to oil.
This needed to be oiled for cooking and being outside. It is covered or brought inside during inclement weather.
Ready for the first use, and it looks great!