# Creating a Live-Edge Copper Epoxy Corner Bar

**URL:** <https://makermattdesign.com/t/creating-a-live-edge-copper-epoxy-corner-bar/372>\
**Category:** General\
**Tags:** woodworking, epoxy\
**Created:** [May 10, 2025, 12:49pm UTC](https://makermattdesign.com/t/creating-a-live-edge-copper-epoxy-corner-bar/372 "2025-05-10T12:49:04Z")\
**Posts on this page:** 1\
**Page:** 1

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**Author:** ![Matt](https://makermattdesign.com/letter_avatar_proxy/v4/letter/m/a6a055/32.png) [@Matt](https://makermattdesign.com/u/Matt)\
**Post date:** [May 10, 2025, 12:49pm UTC](https://makermattdesign.com/t/creating-a-live-edge-copper-epoxy-corner-bar/372/1 "2025-05-10T12:49:04Z")

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# Crafting the Perfect Maple Bar: A Detailed Guide to Creating a Live-Edge Maple and Copper Epoxy Corner Bar

## Executive Summary

This report outlines the comprehensive procedure for creating a high-end corner bar using two 10’ x 2’ maple slabs with a 45-degree miter joint. The project incorporates live edge detail, epoxy fills with copper metal-flake, and structural reinforcement for a durable, functional piece. The finished bar will feature a seamless corner design with a sparkling copper-infused epoxy surface that accentuates the natural beauty of the maple while providing a durable finish that catches overhead lighting.

## Materials List

| Item | Quantity | Specifications | Purpose |
| --- | --- | --- | --- |
| Maple slabs | 2 | 10’ x 2’ x 2.5" thick | Primary bar material |
| Deep pour epoxy | 3-4 gallons | Clear, UV-resistant (e.g., TotalBoat ThickSet) | Void filling and top coating |
| Copper metal-flake | 16-24 oz | Fine grade | Decorative element in epoxy |
| Steel U-channel | 2 | 24" length, 1/8" thick | Structural reinforcement at joint |
| Threaded inserts | 8-12 | 3/8"-16 thread, 1" depth | Mounting hardware |
| Hex bolts | 8-12 | 3/8"-16 thread, 2" length | Securing to cabinet frame |
| Wood screws | 12-16 | #10 x 1.5" | Securing U-channel |
| Epoxy adhesive | 1 kit | High-strength structural (e.g., West System G/flex) | Gluing the miter joint |
| Dowels or biscuits | 8-10 | 3/8" or #20 size | Additional joint reinforcement |
| Sanding discs | Various | 80, 120, 180, 220, 320, 400 grits | Surface preparation |
| Finish sealer | 1 quart | Clear, food-safe (e.g., Rubio Monocoat) | Final protective coat |
| Silicone mold release | 1 can | Spray type | For creating dam forms |
| Mold-making materials | As needed | Melamine board, silicone caulk, hot glue | Creating epoxy dams |
| Respirator | 1 | N95 or better | Safety equipment |
| Nitrile gloves | 2 boxes | Chemical resistant | Safety equipment |
| Mixing cups/buckets | 10-20 | Graduated measurements | Epoxy preparation |
| Stir sticks | 20+ | Wooden or plastic | Epoxy mixing |
| Heat gun | 1 | Variable temperature | Removing bubbles from epoxy |
| Level | 1 | 4’ or longer | Ensuring level installation |

## Detailed Procedure

### 1. Initial Assessment and Preparation

1. **Slab Assessment**

2. **Workshop Preparation**

### 2. Milling and Flattening

1. **Initial Planing**

2. **Void Preparation**

### 3. 45-Degree Miter Cuts

1. **Layout Preparation**

2. **Cutting Process**

3. **Joint Preparation**

### 4. Structural Reinforcement

1. **U-Channel Installation**

2. **Threaded Insert Installation**

### 5. Epoxy Filling of Voids

1. **Preparation**

2. **Epoxy Mixing and Pouring**

3. **Curing**

### 6. Final Assembly

1. **Test Fitting**

2. **Gluing the Miter Joint**

### 7. Final Surface Preparation

1. **Leveling the Surface**

2. **Edge Preparation**

### 8. Full Epoxy Encapsulation

1. **Dam Creation**

2. **Final Epoxy Pour with Copper Flake**

3. **Surface Finishing**

### 9. Installation

1. **Transport Preparation**

2. **Mounting**

## Key Questions to Address

1. What is the exact environment where the bar will be installed? (Temperature fluctuations, humidity, direct sunlight can affect epoxy and wood)
2. What type of cabinet frame will support the bar top, and who is responsible for building it?
3. Are there specific lighting fixtures planned for above the bar that might affect the copper flake selection?
4. Is there a preferred finish sheen (matte, satin, gloss) for the final epoxy surface?
5. Are there any specific areas of the live edge that should be preserved or highlighted?
6. What is the timeline flexibility for the project, considering multiple epoxy pours and cure times?
7. Is there a preferred edge profile where the bar top meets the user (rounded, beveled, etc.)?
8. Are there any specific items to be accommodated in the design (drink rails, bar mats, etc.)?
9. What is the expected usage level and what types of cleaning products will be used?
10. Are there any electrical or plumbing elements that need to be incorporated into the bar top?

## Project Schedule

| Phase | Task | Duration | Notes |
| --- | --- | --- | --- |
| 1 | Initial assessment and material procurement | 1-2 weeks | Includes ordering specialty items |
| 2 | Planing and initial milling | 2-3 days | Requires large equipment |
| 3 | Void removal and preparation | 1-2 days | Detail work |
| 4 | Cutting 45° miters | 1 day | Precision critical |
| 5 | Creating reinforcement recesses | 1 day | Detail work |
| 6 | Installing reinforcement | 1 day | |
| 7 | First round of void filling | 3-4 days | Includes 72-hour cure time |
| 8 | Surface leveling and preparation | 2 days | |
| 9 | Second round of epoxy fills if needed | 3-4 days | Includes 72-hour cure time |
| 10 | Final surface preparation | 2 days | |
| 11 | Full epoxy pour with copper flake | 4-5 days | Includes 96-hour cure time |
| 12 | Final finishing and polishing | 2 days | |
| 13 | Installation | 1 day | |
| **Total** | | **3-4 weeks** | Not including procurement |

## Information Resources

1. **Epoxy Suppliers and Techniques**

2. **Woodworking Resources**

3. **Material Sources**

4. **Technical Specifications**

5. **Safety Information**

This comprehensive plan provides a foundation for creating a stunning maple and copper epoxy corner bar that will serve as both a functional piece and a showstopping design element. The detailed procedure ensures structural integrity while highlighting the natural beauty of the maple and the decorative qualities of the copper-infused epoxy.

#WoodworkingProjects #LiveEdgeBar #EpoxyResin #CustomFurniture

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