**Strap in, this is a longin’ (but a goodin’!)…I’ve since learned that it’s better to blog as I go instead of waiting till the end. I can go much more step-by-step that way. Live and learn!**
Perhaps you remember our b-e-a-utiful bar cart I showed off on Monday? Oh you don’t? Well let me refresh your memory:

Today, that little copper tray is going to get its day in the sun. We started knowing basically what we wanted in the bar piece: reclaimed top, plumbing skeleton, and tray underneath. So, naturally, after we bought the plumbing and put it together, I drew up a plan for a little tray that could sit on the cross bars and hold fun things like shakers and koozies. Here’s the plan:

Simple enough, right? The tray would have cut outs for the plumbing to go through and would be supported by two cross bars in the plumbing. See them there at the bottom?

Let me tell you though, I would not have gone through the trouble of making nicely mitered corners if I had known its fate. At this point, we didn’t know what the finish on the tray would be, maybe stain? Paint? The world was our oyster! We wanted to wait and see what it looked like with the rest of the piece before we decided. Whatever the finish, the tray had to get made, so I cut the wood to make some progress.

After the border wood was cut, our first stop on the finish train was stain. The thought was if we could get it in the same color genre as the top, we’d be in business. Well, after trying all kinds of stain combination alchemy, this is the best we could do.

No cigar. It’s better to be off by a mile than off by an inch in these cases (as The Aceman says) because if it’s close but not exact, it looks like you missed the mark. Go with something completely different but complimentary, and it looks totally intentional. There’s your tip for the day! So needless to say, stain was out.
We built the tray the rest of the way and started brain storming.

Staring at this set up we realized paint probably wasn’t going to look great, and then Mike came up with the idea of lining it in metal. Um, yes please! (It sounds like it happened overnight, but really we were staring and brainstorming for a good two weeks!) We had no idea how to exactly implement the plan, but a few YouTube videos later and we figured we’d be able to work something out. As for sourcing the copper, a quick google search came up with www.basiccopper.com, they sell rolls of copper in tons of different lengths and thicknesses. For $37 we had ourselves an 18”x4′ sheet of 5 mm copper. And quite a project laying ahead.
The copper arrived, and things started to get real.

Yes, I am a dork. Anywho, The copper sat in the box for another few weeks as we formulated a plan and I studied for my comprehensive exam. When the exam was over, I finally got the courage up to start working with the copper. But how to wrap it so it’d lay flat? Good question. I made a couple of paper templates by just taping some scrap paper and seeing where things would need to be folded or cut for it to fit together.



The plan was to have the shorter side’s (on the right in the photo above) copper fold under the front, so that even if the measurement was a little off, everything would be covered in copper. I.e. I put on the side copper first, and then the front to kind of cover up the overlay seen in the photo. We didn’t want to have to rely on my less-than-exact cutting and measuring skills to make sure the ends met perfectly. So I unfolded the templates, measured away, and marked the copper with a pencil.


Cutting was the easy part, a pair of scissors and I was in business!

Once I had the sheets cut to size, I basically just carefully bent it over the appropriate side, and amazingly, they all fit! It was a nice perk that the copper was strong enough for the job, but soft enough to be cut with scissors and bent by hand! (I must have been in a copper daze because I didn’t take any pics
) I removed each piece of copper and measured out where I wanted to attach it to the wood, placing each nail two inches apart. The tip of a mechanical pencil was enough to make a mark where each nail would go.


I used some brass brads and just tapped them in one by one and attached the copper the same way on the underside of the tray. In an interesting side note, we found out that Mike though brass and copper were the same color during this little project! He is colorblind, but it was still a surprise to me when he said we should just use brass because it “looks the same as copper, but cheaper!” I couldn’t help but giggle, does that make me a bad person?


Oats was intrigued, clearly. While I was doing all the light copper work, Mike was working on the bottom copper.

Mike had cut it to size and then used a 1.5 inch hole saw to cut out spots for the legs to go through.


We gingerly placed the sheet into the tray, and viola! We had a tray! (Placing it on the plumbing structure is a story for another day…)





See how it even makes a nice glow on the floor? Ahh, I love that tray! (Also, please excuse the garbage bags at the end of the hall, they’re filled with clothes heading to the donation bin. At least I’m keeping it real!)
Phew, and that’s the long winded story of the copper tray. If you stuck with me, you’re the best!
Have you ever used copper or some other metal to line wood? I highly recommend it!