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Small Projects #57: Pool Table Rebuild

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Blog entry by Madmark2 posted 12-13-2021 12:10 AM 618 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 56: Walnut End Table Done Part 57 of Small Projects series Part 58: Rick Head Gadget Box »

Neighbor bought a used pool table. The bed and legs are OK, but the tops & sides are particle board covered with wood grain vinyl and are in mid decomp. The table and rails were not designed to be refelted as the rail assembly is two glued pieces with the felt trapped in-between.


Decomp on skirt, rails crumbling.

We’re using clear 1×6 pine for the tops and 2×4’s for the rail backs. When we stripped the felt off we found we could easily strip the rail bumper rubber off the particle board. They were glued with contact cement but the particle board was so rotten the rubber came off and brought about 50% coverage with breakoffs from the particle board. They’re easy enough to sand clean—a task delegated to the neighbor.

The rubbers seem to be 60°-60°-60° equilateral triangles with a groove in the bottom. The wide side of the groove goes up.

The 2×4 rail supports need to be beveled at the 60° angle so the triangle tops are even with the top of the sides. The bevel on the top side is wide enough for the rubber strip to be glued onto. The edge is undercut to tightly wrap the felt and leave room for staples.

The rail support and top form a sandwich. A 3/4” by 2” rabbet is cut on the table saw. I set the blade using the DRO to .750” and the rip fence to 2” less 3/32” thin kerf to cut the short side of the rabbet. Raising to blade to 2.000” and setting the rip fence to 3/4” let me rip the wide side of the rabbet. The result was a perfect fit.


Rail support and top.

The corner pocket rail ends miter at 45°, while the side pockets are mitered at 15°.

The top pieces are about 36” wide and curve in at the pockets. We traced the piece on the freshly ripped 1×6 stock and cut the curve with the band saw. We saved the offcut for use as a template. A quick pass on the oscillating 4” belt sander took out the texture from the bandsaw. Finally we routed an ogee on the outside edge. The profile was almost an exact match.


First cutoff is template.

The rail support end for the corner pockets needs to be beveled but not the side pocket end. There is also a 2×1-3/4 notch on each end that was easy to cut on the bandsaw.

The third piece of the assembly is the skirt. The original was 1/2” particle board and I’m using some scrap 1/2” ply as a replacement. Neighbor says he’ll stain later.


Ply skirt.

All in all it took about 1:45 to make the first of six. Now knowing the process and having a good template batching the last 5 should go quickly.

… time passes …

I roughed all of the rails. The 60° bevels were cut first.

The tall bevel had a bit of pucker factor as it was cut without an insert. My gawd all that exposed blade looked like the jaws of hell!
Once the tall edge was beveled, the blade was lowered for the short cuts. The trimmed square ends had their bandsaw work done in prep so just final trim and bandsaw work is left

… the next day …

Only took about 2 hrs to make the remaining five sets. First step was labeling the originals with their sequence and master dimension. Then each piece was trimmed to the master dimension and labeled. Once labeled the miters were cut zip-zap on the Incra M1000. All the angles needed had presets so switching angles only takes a moment and no double checking needed.

Layout for the bandsawing of the curves was easy as I had saved the first cutoff as a pattern.

All thats left is some sanding as router prep and the edge routing. I had lifted the router plate, router, bit, & all and set it aside. So the plate just needs to be dropped back in place and the bit is ready to go. This is why I like plate mounted routers instead of ones with the router fixed to the stand. Esp for a saw side router.

-- The hump with the stump and the pump!



2 comments so far

View Ransavi's profile

Ransavi

2 posts in 154 days


#1 posted 12-13-2021 06:19 AM

great

View robscastle's profile

robscastle

8541 posts in 3654 days


#2 posted 01-09-2022 11:02 PM

Glad to see it hasn’t got you all snookered!

-- Regards Rob

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