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Creating Modules
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4x20.gif (55 bytes)Consider using 1/2" apple ply cabinet-grade plywood for a strong, stable playing surface. These come in 5'x5' and 4'x8' sheets. Shown is a layout template based on two 4'x8' sheets that yields 6 standard modules, 2 crossover modules, a corner, a tee or wye, 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.

4x20.gif (55 bytes)I made construction of my first few box frames harder than necessary. Instead of dovetailing or using a corner lock bit, I cut a simple mitre and used biscuits to join the corners. Check at Woodcraft® or Rockler® for corner lock bits - or simply butt or route a step at the ends to keep joints square.

4x20.gif (55 bytes)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
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For the leg supports, I started with a 1" sheet of cabinet-grade plywood. This was then cut into 16"x18" sections and the arch was cut on a band saw using a centering hole and jig. Take time to break sharp edges with a roundover bit to reduce splinters and chipped edges...

Module Types
4x20.gif (55 bytes)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

segment along same edge) or crossover segments (closest tracks switch edge from far to near sides). Only two crossover segments are needed to really add variety - one that crosses from left to right, and the other from right to left.

4x20.gif (55 bytes)One of the modules shown is short. Longer modules can be used as well - but they won't fit a typical backseat or trunk...

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Layout elements
4x20.gif (55 bytes)Below are some typical arrangements that really work in this 18" wide format with minimal modification. Using custom or cut track pieces expands your options dramatically. Shorter and longer segments can be used to accomplish creative solutions as well.
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