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With the tools you have I would mark out (slightly oversize) lines with a square along a length of wood, cut them to the line on the bandsaw (by sight - not using the fence - OR use a bench-hook and a handsaw), sand one face square, use jig to sand to final length.

You could make a simple jig to sand your blocks to a uniform length on the disc sander, as below. Make a board to run along the fence. On top place a stop (X) roughly where your shortest block is (A). Underneath you want another stop to hit the front of the table - ideally this should be...

Tried my Aerolite today but noticed something strange. I thought I would dilute the remnants in the container to clean it out. After adding a lot more water and giving it a brisk stir it began to expand, a bit like foam - is this normal? - give it a try.

Nice looking board. Unless you are going to put this on display I would stick to a roundover for the simple reason that, after prolonged use, your chamfer will end up as a roundover (as marcros says^^^) through wear.

You could also get a few spare nuts, drill the thread out and use them as thick washers to move the nut to the end of the thread.

I'd go with the router and clean-up. Is this a one-off though?

That would be my first job then - to adjust everything so you can get a socket over it.

Are you saying there isn't enough room to wind the nut past the coach bolt then?

How about something like this

Clearly, they do! :)

Welcome to the forum. I suspect you'll be able to give as much advice as you seek?

I paid about £11 for a small tub - 1kg (I think) from Isaac Lords

What's the bet that someone will be on soon to tell you you should have bought a Festool?? :)

The above is what I got when I just logged in - that's the number watching the site. 50 views doesn't mean anything. A little patience goes a long way!

Well, if lockdown happens in the next ten minutes I don't think I will need to try this!!!

I suspect they probably just thought they were nice patterns rather than anything else? Nice box though.

I feel sorry for the youth of today who grew up with 'online'. Everything they have ever had an opinion on will have been recorded and will always be there for someone to dredge up later in life. Never allowed to grow up and develop!

Can you imagine the screening process they'll put potential contestants through now - 'Yes, yes, that's a lovely tatoo of a rose but my great, great,,,,,,,,,,,,,,grandfather was a Plantagenet and we've been caught out once already, NEXT....'

There's a lot of that. This was the first one I found doing a search - how to apply tung oil. You can now get modified tung oils that dry quicker - new to me! I have only used it once and it was too long ago to remember specifics but I do remember the time it took!!

I thought the drying time - between coats - was days for pure tung oil and months for it to fully cure?