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Construction

Table Alpha

Construction!

Materials

4x8 ¾” hardwood birch plywood- a nice high quality wood, with 9 plies and no voids. These were used for the primary bases.

4x8 ¾” construction grade plywood- cheaper stuff, these were used to cut out the main railing pieces.

4x8 ¼” oak plywood- used for the racetracks and infields.

¼” headliner foam used for the infield padding.

2’ wide foam 1” thick, used for the rail padding. 11 linear ft per table.

Vinyl, various types.

Velveteen (2 tables), speed cloth (1 table)- used for the infield surfaces.

3M #77 spray adhesive

Elmer’s carpenter’s glue- to glue the railing pieces together and the racetrack to the main surface.

Folding banquet table legs- 2 sets 31”, 1 set 24”

A bunch of 1 ¼” wood screws.

6 t-nuts/table

And about 300 staples per table.

Other things I had to buy

3 5/8” hole saw

Metal bar for a jig.The jig didn’t work very well with my jigsaw. The blade kept bending, so we ended up just using the bar as a guide to draw the lines. We drilled 5/16” holes at the pivot point thru all 3 boards, and dropped a #10 screw thru the bar and the holes. We kept a screw in the holes at each end at all times during cutting. This helped keep the boards aligned.

Here are my construction pictures, in roughly chronological order

Drawing the cut lines for the oval ends

Cutting the oval

Finished cutting the oval

We cut the oval on all 3 sheets at once

Main railing piece has been cut

Cutting out the railing lip (leftmost line). You can also see the other lines. Rightmost line will be the infield/racetrack cut, and the middle line is the centering line for the cupholders.

We screwed the main rail piece onto the railing lip from the top, so the screws wouldn’t interfere with staples later. We also used a lot of glue.

Underside of a finished rail, in front of a big piece of scrap.

A big-ass roll of foam.

Wrapping and stapling the vinyl. Here we draw the wedges at one end.

Closeup of the vinyl stapling

Finished stapling this end, just need to trim the excess off.

All 3 rails are finished!

Padding the infield.

The underside of the infield.

Putting the scrap to use as a cutting board.

Will works on the cup holes.

The hole saw is 3 5/8… The cups are 3 11/16. Doh. Fire up the dremel.

Holes.

More holes. 30 holes.. 30 dremelings. Is dremeling in the dictionary?

Let the staining begin. Alpha gets its first coat.

Bravo pre-painting.

Charlie, Bravo, and Alpha, pretty much finished. Do we have a glazed look in our eyes? It’s 1130pm on Friday. Will heads back to his base in about 9 hours.

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