I wanted a NICE poker table...trouble is...I don't have a poker room...or a man cave....or a game room...or a den...you get the idea. We live in a small place without a lot of storage.... So this project was going to have a few challenges. The basic idea was to create what looked like a permanently installed poker table...that could be placed in the dining room on the existing table. It would have to be stored in a smallish closet in the basement and carried up a flight of stairs every couple of weeks for the neighborhood poker game. And of course...I couldn't spend too much $$$ (the wife would have my head).
I looked at a number of DIY table designs and decided I could adapt them to a table topper design that would have all the elegance of a true poker table with the portablility of a table topper. I wouldn't be carrying this topper outside of the house, so it didn't need to go far, but it did need to be mobile enough to get in and out of that basement ...solo. Having used a number of different off the shelf toppers, I REALLY didn't want seams...they are troublesome...and get in the way of dealing....and more importantly to an obsessive-compulsive eye like mine, they are just unsightly. I wanted a shiny race track and smooth speed cloth playing surface. The first thought was just to build a table much like many of the others you've seen, but just leave the legs off. No way that was going to make it up those stairs and around that corner...even with help. But I couldn't figure out how to get around hinges and seams. Finally I conceptualized a three piece design that would minimize the impact of the seams, leave a single piece smooth playing surface and remain easy enough to move around the house and store in our limited space. The basic idea is to build a one piece table with rail, racetrack and a removable insert (playing surface) and then split the table (less the insert) in half and connect them with a pair of hasps that will be hidden under the insert.
As we prepare this project there will be 5 major phases to this project:
Phase 1: Selecting and assembling materials (step 1)
Phase 2: Woodworking (steps 2-11)
Phase 3: Upholstering (steps 12-13)
Phase 4: Finishing (step 14)
Phase 5: Final Assembly (steps 15-19)
Step 1: Select & Assemble Materials
Not to belabor the obvious, but you want to start by thoughtfully selecting your materials. I took my time on this one, nearly 6 months in fact. I didn't want to rush things and at the end of the day what you are looking at is a product of this decision more than anything else. The critical decisions are 1) the vinyl 2) the playing cloth and 3) the race-track veneer. There are a lot of options out there, so look around and see what you have available. For upholstery I ended up at Texas Poker Supply (http://texaspokersupply.com/build-a-table/). They have a full spectrum of materials including cups, vinyls, speed cloths, felts, and the prices are good enough. They will also do custom prints on the cloth if desired. Fabrics are cut in appropriate sizes so you end up doing better here than most bulk suppliers (that make you buy more than what you want). So look around, but the convenience of one-stop shopping is hard to beat.
I recommend taking the extra time and cost to order swatches and spend some time with matching your vinyl and cloth!
The other important piece is the race-track plywood. I ended up with a reasonable birch veneer from my local lumber yard, but if you want to get crazy, check out a fine-woods supplier. Your choices will be limited at standard lumber yards or Home Depot.
Here's the list of what I ended up with:
Upholstery & Cups (Poker Supplier or Fabric Store)
Vinyl & cloth Samples = $4.99 (marine vinyl) + $6.50 (exotic vinyl) + 2.50 (speed cloth) = $14
1) Vinyl (54" wide x 9 ft) = $9.98/ft = $89.82 Brown Crock Vinyl
2) Cloth (54" wide x 7 ft) = $5.98/ft = $41.86 Trump Card Suited Speed Cloth Poker Felt
3) 1" Foam (for Rail) = $54.95 High Density Open Cell Foam 105x55
4) 1/4" Volara Closed Cell Foam -(for playing surface) (60" wide x7 ft) = $3.25/ft = $22.75
Cup Holders (x10) = $6.50 ea = $65.00 Shallow Stainless Steel Cup Holders
Spray adhesive (1 can) = $8
Wood & hardware (lumber yard)
Racetrack - 3/4" Plywood Birch Plywood 4'x8' = $40
Rail - 3/4" Plywood (low grade) 4'x8' = $32
Base - 15/32" Sheathing Plywood 4'x8' = $18 (you could use a thicker piece, but it will add unnecessary weight)
Chest Latches (x2) = $3
Screws 1 1/4' (1 box) = $7 (note: I actually used 1" screws as depicted in the photo-too short. you want 1 1/4")
Staples T50 5/16" (2 boxes) = $2.67 ea = $5.34
Wood Glue
Finishing
Sand paper 400 grit
Sand Paper 1000 grit wet
Sand Paper discs 220 = $6
Polyurethane, 1 qt = $12
Stain, 1 pint
foam brushes
tack cloth
rags
Rubbing compound (for final varnish buffing) = $5
Rotary Buffing pad
Wood filler (optional)
Covers
1 Large Drop Cloth = $40
Bottom Pad (carpet Pad) = $25
Approximate Total cost = $400
Tools Used
Jig Saw
Finishing sander
Drill/screwdriver
Hole Saw 3"
48" Metal Ruler
Framing Ruler
Combination Square
Rafting Square
Router (with straight bit)
Clamps (8-10)
Belt Sander
Putty knife
Table
Saw Horses
Electric Stapler
Rotary cutter & mat
Scissors
Sewing Machine
A couple of cases of your favorite beer. It's going to take a while, so slow down and enjoy it. The more time you take, the better your final product will be.
