 Consider using 1/2" apple ply
cabinet-grade plywood for a strong, stable playing surface. These come in 5’x5’
and 4’x8’ sheets. Two 4’x8’ sheets yield 7 standard modules, 2
crossover modules, a corner, and 4 ends. You will also need enough 1"x4" lumber
to construct the sides and ends of each module. I used poplar that came from a
‘real’ lumber yard – it strikes a good balance for cost and strength and is
fairly easy to cut, route, and sand.I made construction of my first few box frames harder than
necessary. Instead of using a corner lock bit, I cut a simple mitre and used biscuits to
join the corners. By contrast, the corner lock joint is self-aligning, increases glue
surface, and makes clamping a breeze. Check at Woodcraft® or Rockler®
for bits.
An inside edge lip is needed on all sides and
ends so the table top can be dropped into place and glued. Cut this before you assemble
the box. Also consider using a small roundover bit on the outside edge for splinter
control and to reduce elbow, chin, and head dents later...
Leg supports
For the leg supports I started with a 1"
sheet (it might have been 31/32") of apple ply cabinet-grade
plywood. This was then cut into 16"x18" sections and an arch was cut on a band
saw using a centering hole and jig. Take time to break sharp edges with a roundover bit...
Module Types
Using
standard end dimensions, a wide range of complimentary straight, crossing, wye, tee, and
other modules can be imagined. These can be standard segments (closest tracks enter
and leave |
