These beer flight trays are used to sample multiple home brews. This is one design I came up with.
Step 1: Materials and Tools
These flight trays can be made from many different materials, I chose to use poplar
2 1/2" Forstner bit
1/2" drill bit
Jig saw / Band saw
Sander / sanding block
Many of these tools can be replaced with hand tools if needed
Step 2: Cutting Your Material
The main piece is 20" long, 4 1/2" wide and 3/4" thick. The two legs
are 2" high, 4 1/2" wide and 3/4" thick. The dowel is 1/2" dia and 14" long.
Step 3: Marking and Cutting the Holes
For the holes, I used a 2 1/2" Forstner bit. I started to mark the piece
of wood leaving 1 1/2" from one end to the edge of the first hole, leaving 1" in between each hole. At the end I marked out for a 4 1/2" long handle and 1 1/2" wide. The handle can be cut with a band saw or jig saw.
On the legs I marked in the middle of the piece 1/2" from the bottom, using a 1/2" drill bit I drilled 1/2" deep for the dowel to fit into.
Step 4: Finishing
I rounded some edges on a belt sander and also used a router on the
top edge to add some more detail. This is optional as you can just sand the edges by hand if you prefer.
Next I glued the pieces together using a pin nailer just to hold it together while the glue sets. One final sand, stain and polyurethane if you prefer.