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DIY Desk with Metal Inlay

Get the modern industrial look with this wood and metal desk! The brushed aluminum inlay and feet combine with navy blue for a modern look to your office.

Combine the sleek look of brushed aluminum with the sophistication of deep navy blue to create this amazing DIY wood and metal desk! Get the free woodworking plans and step-by-step tutorial at The Handyman's Daughter. | modern desk | mixed materials desk | modern industrial | office ideas | home office ideas | stainless steel desk | #woodworkingplans | #woodworker | #woodworking | #diyproject | #desk

My husband asked me to make him a desk over a year ago, and I'm finally getting around to building it! Oops! His only requirement was that it was long enough for both he and our son to sit at together. This wood and metal desk will be perfect for all their geeky endeavors, and I finished it just in time for Christmas!

This post is sponsored by Osborne Wood, and contains affiliate links for your convenience. This means that I may receive a small commission from any purchases made through these links at no cost to you.

I had my eye on the Weston Fusion table legs from Osborne Wood for months before starting this project. The square shape coupled with the metal feet melted my modern/industrial loving heart!

I love the wood and metal legs of this desk!

I originally planned to make a new dining table with these gorgeous legs. But I was reminded yet again about my promise of a new desk, so I decided to change gears. This design would work both for a table and a desk, though!

Materials Needed for Wood and Metal Desk

Don't forget your safety gear when woodworking! Here are my recommendations for safety glasses and ear protection. No excuses!

How to Make this Wood and Metal Desk

To bring more of that gorgeous brushed aluminium into this wood and metal desk design, I scoured the internet for something I could inlay into outside edge of the desk. I discovered a seller on Etsy that sold 2" wide brushed aluminum banding. Perfect!

Now that I had the banding, I worked my way backward. Using a 1 x 4 board for the apron gave me 3/4" above and below the band. It will cover up the entire frame and edges of the desktop, giving it a clean, modern look.

Assemble the Frame

Knowing the dimensions of the apron, I could plan the rest of the desk. The frame will incorporate the legs, which are 3" wide. Trim 1/4" off each side of the 2 x 4 boards to create 1 1/2" by 3" boards.

Trim 1/4" off each side of the 2x4s to create 3" wide boards.

Cut two of these boards to 52" long for the front and back, and cut five at 16" long for the sides and center supports. Drill pocket holes into both ends of all the pieces.

Cut the frame pieces for the wood and metal desk.

Join two legs together with a 16" piece with wood glue and 2 1/2" pocket hole screws. You may need a right angle drill attachment if your drill doesn't fit between the two legs. Repeat for the other set of legs.

Attach the legs together with one 16" piece.

Join the pairs of legs together with the 52" pieces. Then attach the remaining three 16" pieces down the center for additional support.

Create the frame for the wood and metal desk.

Assemble the Top

It's always a challenge to find straight 1 x 6 boards, especially at the big box stores. I typically have better luck at small, independent lumber yards that get nicer stock, plus sometimes it's cheaper too!

Cut four 1 x 6 boards to 58" long. Drill pocket holes down the length of all but one board. Then glue and screw them together with 1 1/4" pocket hole screws. Use clamps to make sure everything is straight and flat before attaching them together.

Plank the top 1x 6 pieces together with pocket hole screws.

Double check that the planked top matches up perfectly with the edges of the frame. If it's slightly too big (lumber sizes can vary slightly), trim off the excess on a table saw. No table saw? Check out this post on how to cut perfectly straight lines with a circular saw!

Make sure your planked top matches up perfectly with the edges of your wood and metal desk frame.

When you attach the top to the frame, you need to account for wood movement. Changes in humidity and seasons can cause your wood top to expand and contract. This can ruin a perfectly good desk top over time.

To allow for wood movement, I used these figure 8 brackets. They give the wood a little bit of wiggle room, while keeping the top securely fastened to the base.

Figure 8 brackets allow the top of the wood and metal desk to move with the seasons without ruining the top.

To install them, just drill a shallow hole with a 3/4" Forstner bit slightly off the edge of the frame. The top of the bracket should be flush with the frame when it's screwed in place. The other side of the figure 8 is attached to the underside of the desk top with 3/4" screws.

How to Attach Figure 8 Brackets for Table Tops

Create and Attach the Apron of the Wood and Metal Desk

This is the trickiest part of the build. In order to recess the metal band into the face of the apron, you need to cut a shallow channel for it to sit in. You can skip this step entirely if you want to attach the band to the face instead.

I finally bought a dado stack for my table saw (which also required a special brake and insert for my SawStop). I have a few projects that I've been putting off because I didn't have a dado blade, so it was time to shell out the cash for the whole setup. You can also accomplish this with a router if you prefer.

Cut two 1 x 4 boards to 59 1/2" and two to 23 1/2". You'll be cutting out a 1/8" deep channel two inches wide down the center of each board.

Set the outside edge of the dado stack so that it's 3/4" in from the edge of the 1 x 4 boards. I found it easiest to mark that point on the side of the board to be cut, then adjust the fence until the edge of the blade lined up with that mark.

Cut the first dado, then flip the board around and cut the other side. You'll be left with a bit in the middle, which you can then cut away with a third pass.

Cut the channel for the metal band with a dado blade.

Test the fit with the metal banding. Now you can start to see how it will all come together!

Test the fit of the metal banding of this wood and metal desk.

Miter the ends of the 1 x 4 boards with a miter saw. I suggest cutting the long boards first, clamping them to the desk frame, then cut the shorter ones to fit.

Cut the ends of the 1 x 4 boards at a 45 degree angle.

Drill countersink pilot holes along the length of the 1 x 4's in the upper half of the INSIDE the channel. These will be hidden behind the metal banding, but make sure that the screw head will be completely below the surface of the wood. You can learn more about this technique here.

Drill countersink pilot holes on the upper edge of the channel of the wood and metal desk.

Attach the 1 x 4 pieces to the outside edge of the frame with 1 1/2" flat head screws, keeping the top edge flush with the desk top.

Attach the apron to the desk frame, keeping the top flush.

Fill in any gaps in the desk surface with wood filler, then sand smooth with progressively finer grits of sandpaper.

After much debate about color, my husband finally settled on dark blue. Benjamin Moore's Hale Navy is really popular, and for good reason! It's a gorgeous navy blue with gray undertones that looks great with pretty much everything, especially brushed aluminum.

Cover up the metal feet with painters tape, then give the entire desk a few coats.

Cover the metal feet with tape before painting.

Now, for the finishing touch! Cut a strip of the 2" wide brushed aluminum banding long enough to go all the way around the desk. Be careful not to bend or crease it! Mine was rolled up pretty tight, so I helped it relax with the heat of a hair dryer until it lay flat.

Use a hair dryer to help the metal banding relax and flatten out.

Apply construction adhesive to the groove. Don't overfill it, and keep it away from the edges so it doesn't ooze out. I used a wood shim (I have tons of them left over from my wood shim barn door) to smooth it out.

Use construction adhesive to attach the metal banding to the desk.
Clamp the metal into place and allow to dry.

Insert the metal band into the groove, and use a scrap piece of 2" wide board to clamp it into place. I attached one long end and one short end at a time because I ran out of clamps!

Make a crisp crease at the corners by clamping two boards at a 90 degree angle to each other.

Use clamps to get a crisp corner on the edge of your wood and metal desk.

Once the adhesive cures (I left mine in clamps for 24 hours), use a razor blade to cut away any adhesive that may have oozed out. Touch up any spots where the paint was removed.

Where the two metal ends meet at the back, I attached a 2" mending plate. This covers up the seam and makes sure the band stays in place.

Attach a mending plate to the back of the wood and metal desk to cover up the seam in the metal band and prevent it from moving.

Finally, my husband's office has a new desk!

Give your home office the modern/industrial look with this wood and metal desk!
The navy blue paint contrasts beautifully with the brushed aluminum accents of this wood and metal desk.

The dark navy blue contrasts beautifully with the brushed aluminum. The details really make this wood and metal desk pop!

Make your home office pop with this wood and metal desk!
This wood and metal desk is the perfect place to work!
I'm loving these wood and metal desk legs from Osborne Wood!

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Not quite the wood and metal desk you were looking for? Try this DIY industrial computer desk!

gray stained desk with metal accents

You can create your own desk using IKEA Kallax and Rast furniture pieces too!

This IKEA desk hack is easy to make with a Rast dresser, Kallax storage unit and a few boards! See the full tutorial on The Handyman's Daughter

Or try one of these other DIY desk plans!

15 DIY Desk Plans for your Home Office

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Combine the sleek look of brushed aluminum with the sophistication of deep navy blue to create this amazing DIY wood and metal desk! Get the free woodworking plans and step-by-step tutorial at The Handyman's Daughter. | modern desk | mixed materials desk | modern industrial | office ideas | home office ideas | stainless steel desk | #woodworkingplans | #woodworker | #woodworking | #diyproject | #desk
Make this wood and metal desk for your home office! This simple desk design is perfect for highlighting the metal inlay and feet. Get the free woodworking plans at The Handyman's Daughter! | DIY desk | desk inspiration | home office idea | building plans

Judy

Tuesday 15th of May 2018

That's amazing. Great job. I will be featuring this tonight at my Swing into Spring party that opens at 8pm EST. Please stop by and pick up an I've Been Featured button. Thanks. http://diybydesign.blogspot.com

Jann Olson

Monday 14th of May 2018

I love the combination of the wood and metal! Thanks for sharing with SYC. hugs, Jann

Rhonda

Friday 11th of May 2018

I love how this turned out. I think it's the color combination that makes it pop. Thanks for sharing on Sunday's Best.

Chas

Wednesday 9th of May 2018

Thanks for sharing on To Grandma's House We Go!

Debrashoppeno5

Monday 7th of May 2018

This desk is fantastic looking. I bet your husband is thrilled.

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