Poker Table Construction - Black Racetrack Table - Supplies


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SUPPLIES AND COSTS
2 Sheets of 4' x 8' x 1/2" Oak Plywood
It seems that 3/4" plywood or MDF (Medium Density Fiberboard) are the most popular choices of lumber for a poker table project. I chose 1/2 inch because I wanted the table to be lighter, and with the addition of the baseboard, the total thickness would be 1" in some areas.
Vendor: Home Depot
Cost: $69.98 (2 sheets @ $34.99)
Wood Glue
Not much wood glue is needed, and you could possibly event get away with not using it, but it's strongly recommended for the contruction of the rail.
Vendor: Home Depot
Manufacturer: Titebond Original Wood Glue
Cost: $4.99
Case of Beer
I chose the champagne of beers. The "High Life" seemed fitting for such a masculine project.
Vendor: The Cellars Wine and Spirits
Manufacturer: Miller Brewing Company
Cost: $13.99
1 Inch High Density Rail Foam
I was excited to get my project started and didn't want to wait for shipping of any items so I got my rail foam from Joann Fabrics. They didn't have a single sheet with the width I needed so I connected two sheets with hot glue. I would highly recommend NOT doing this. Nobody but I can really tell the difference, but I can feel some of the hardened glue in the seam of foam under the vinyl on the rail at the end of the table. I strongly recommend getting a single sheet of 1 inch high-density closed-cell foam. The best deal I have found is through YourAutoTrim.com. A single sheet of High Density 1" thick X 108" long X 54" wide foam is about $30 ($21.95 plus shipping). I have ordered from them before and have been pleased with the quality and speed of shipping. It is cheaper and best of all, NO SEAMS!
Vendor: Joann Fabrics
Cost: $40.93 (2.75 yards @ 14.56/yard)
1/4 Inch Closed Cell Volara Foam
The quarter-inch foam is used for the playing surface, below the fabric. I highly recommend the Volara foam from YourAutoTrim.com. It looks and feels similar the foam on the underside of a mousepad.
Vendor: YourAutoTrim.com
Cost: $24.51 (2.25 yards @ 8.95/yard + shipping)
Spray Adhesive
For securing foam to the rail and playing surface.
Vendor: WAL-MART
Manufacturer: Duro All-Purpose Spray Adhesive
Cost: $7.49
Staples
You are going to use ALOT of staples. I'm unsure of the exact count, but get a couple boxes if you want to be safe.
Vendor: Home Depot
Manufacturer: Arrow
Cost: $7.90 (2000 staples)
Vinyl
I used a black faux leather vinyl from Joann Fabrics. Joann had a bunch of assorted vinyls in the closeout sections, but this stuff was top notch. I figured if I was going to put in this much effort into a table, I would regret not getting the good stuff.
Vendor: Joann Fabrics
Manufacturer: Whisper Vinyl
Cost: $34.06 (2.75 yards @ 11.99/yard)
T-Nuts / Bolts / Washers
8 T-Nuts (5/16" x 3/8") are placed into the wood beneath the playing surface to secure the playing surface to the baseboard. 8 bolts and 8 washers are used to connect the baseboard to the playing surface from underneath the table.
Vendor: Home Depot
Cost: $12.00 approx. (8 T-nuts, 8 bolts, 8 washers)
Mineral Spirits
Helps remove debris and prepares the race track for the application of ployurethane.
Vendor: Home Depot
Cost: $12.75 (1 quart)
Clear Gloss Polyurethane
The key ingredient to protecting the racetrack and giving it its brillliance.
Vendor: Home Depot
Cost: $7.99 (1 pint)
Sandpaper
Before the application of the polyurethane, and inbetween every coat, the racetrack must be sanded using a finer grit between every coat. Grits: 180 - 220 - 320.
Vendor: Home Depot
Cost: $15.00 approx. (assorted grits of sandpaper)
3" Deep Jumbo Drop-In Dual Cupholders
The jumbo cupholders will hold a beer bottle, pint glass, wide low-ball glass, and even a soda in a full-sized coozie. A key element to the table. Available from Smackdogg.com.
Vendor: Smackdogg.com
Cost: $28.90 (10 pack)
Folding Table Legs
Folding table legs for easy storage and portability.
Vendor: Home Depot
Manufacturer: Wadell
Cost: $19.16 (set of 2)
Playing Surface Fabric / Speed Cloth
This turned out to be an expensive item for me. I initially bought a piece of Black Alova Suede for approx. $17. My eagerness to see what the table was going to look like had me place the racetack around the playing surface before it was completely dry... DON'T DO THIS. A few drops of polyurethane on the fabric and you will never get it off... it hardens and looks like someone "jizzed" on your table.
I removed all the staples and re-covered the surface with a piece of faux moleskin for about $25. After the new application, I contacted a local airbrush shop owner at the Mall of America who was confident his artists could airbrush a logo onto the surface. I asked for a small 8" x 8" logo in the exact middle of the table. The guy completely fucked it up by starting to airbrush a huge logo across the entire surface. I caught him doing this and he said he could fix it by going over it with black paint. He then put the small logo on the surface and it looked like crap, and it wasn't event in the middle of the table. They refunded my $40, but I had to re-surface the table a third time.
I used a faux suede for the last fabric surface that ran 9.99/yard. It looks and feels awesome, but the cards don't slide like they did with the moleskin.
If you are interested in applying a logo, there is a process that the casinos use for their tables called dye-sublimation (Example #1; Example #2). It is a digital printing process for fabric. It is fairly expensive. I got a quote for $250 for a single piece from Banner Creations. If you have the budget this is the best option. They will not let you provide your own fabric as some fabric types will melt in their machine... and they run about $20,000 per printer so you can understand why.
Air brushing causes the surface to be crusty. Silk Screening is not that durable and can cause the cards to flip-up.
If you do go with the silk screening option, don't put the logo in the center... put it on one or both sides of the center. This will make your silk screen last longer as the majority of action (raking chips, card action) occurs in the middle of the table..

Vendor: Joann Fabrics
Cost: $23.94 (2.25 yards @ $9.99/yard)

Table Cost Summary

Plywood $69.98

Wood Glue $4.99

Beer $13.99

Rail Foam $40.93

Spray Adhesive $7.49

Staples $7.90

Rail Vinyl $34.06

T-Nuts/Bolts/Washers $12.00

Mineral Spirits $12.75

Polyurethane $7.99

Sandpaper $15.00

Drink Holders $28.90

Folding Table Legs $19.16

Surface Fabric $23.94

Total $299.08

Time Summary 24-32 hours