V. PLywood
- Draw a line across the 4x4 in the middle of the table (this should be the 102-inch line). This line should divide the 4x4 in half the long way. Extend the line up the insides of the table so that it is clearly visible.
- Place the large plywood planks on so that they meet at the line on the 4x4. Make them as flush together as possible. On the ends, they each should come to 0.75 inch of the second to last strut (See Diagram V.b). This shortage on the ends allows the carpet to bend down into the pit (rather than bump out if the angle was sharp).
- Screw the plywood down into the struts using the 2 inch screws. Work from the 4x4 out toward the table ends. Put three screws into each strut in the middle of the table, and four screws into the struts on the ends and the 4x4 junction strut.
- Use the level to ensure that the plywood is perfectly level, both lengthwise and across the table, at every location and especially near the ends. If the surface is not level, use more screws to tighten down the plywood, or knock in a shim. If this fails, use the sander to even out bumps and bulges. Again, be careful not to take off too much. Also, keep in mind that you may need to re-level the table after it stands on its legs.
- Fit in the back board at an angle suitable to you. I shoot for about 45 degrees (the point of the 2x4 is about 1.5 inches from the end of the side beam), but this is trial and error (be careful when testing; there is no carpet yet to dull the ball's force). Bring one 2x4 to each end, and screw it into place at an angle according to the mark using 3 inch screws (See Diagram V.e). This 2x4 gets the most beating of any on the table, so take great care in screwing it in well. You may want to pre-drill the holes to avoid splitting the wood at this fragile junction.
- Turn the entire table over so that it is upside down.
- Place the end and center angled supports in the places indicated in the diagram and screw them in using two or three 3 inch screws on each end (See Diagram V.g).
- Lay the remaining pieces of plywood over the ends where the pits will be and screw them in using the 2 inch screws (See Diagram V.h).
