I wondered about the interior construction a lot, since I needed to cut a piece in both lengthwise and crosswise direction. First off. If you cut in the crosswise direction, the cut edge will be exactly the same as the the ends that came with the original counter. You will likely need to do a little sanding to get to that point. I have a very smooth cutting blade and finished the end with 5 minutes of sanding with 220. The lengthwise direction is finished on each side with a solid bamboo edge (three layers adding to about 1 inch thick). If you cut more than an inch off in the lengthwise direction, you will expose the cross grain of the core. I have dealt with that two ways. One is to just sand smooth and seal with water based polyurethane. Looks pretty good, but clearly different than the uncut edge. The other solution is to rip one lengthwise edge piece from the board. Cut the panel to the desired width less 1" and glue the edge back on. This works great and matches the original edge finish. If you can find bamboo edge banding in your area, that should also work. You could also cut to final size removing edge from both sides. Both sides will match, but not as clean a look as gluing the solid edge back on.
However you decide to do it, hand sanding with 220, knocking off the sharp edges and finishing with 3 coats of water based polyurethane resulted in a beautiful counter that beads water nicely.
Date published: 2020-09-19