Cut the walnut wood to obtain an overall dimension of 48” L x 18” W for the trim and accents. Then cut a 48” L x 18” W piece of birch plywood. Now make a 3/8” groove using the router across the length and running through the center of the board to fit a center rail measuring 36 ¾” L x 1” H x ¾” W and for the "gutter" at the end of the scoring area.
Prepare inlay lines by cutting five grooves, four for the "Scoring" cells and one for the "Foul" line. Proceed to milling of the inlay material. To match the trim, you may use scraps of walnut wood and glue them into the wood using enough pressure till they are firmly set in the groves. Once the glue is set and dry, use a ½” chisel to chip away and plane the top of the inlay making it flush with the surface of the table top.
Sand the playing surface, after the inlays have been thoroughly cleaned. After sanding has been done, use pressurized air to clean and finish the surface.
Use a light-colored stain for the game surface and then apply several coats of polycoat. For the walnut trim you may use "BLO," which is ideal to bring out the richness in the wood.
Glue trim pieces together, then use long clamps to hold them in place and allow to dry overnight. Then remove the clamps and use a ¼’ round-over bit of a laminate trimmer to round-over all sharp edges.Now sand the interior face of all trim before you glue it to the board’s surface. Then apply the green felt to the hardboard before you glue it down. This will give the gutter a cleaner look.
Finally, varnish all wooden members to give your table a shiny, well-polished look.
Things You Will Need
- Birch plywood
- Walnut wood
- Table saw
- Miter saw
- Surface Planer
- Drill (with assorted bits)
- Clamps (various sizes)
- Carpenter’s square
- Tape measure
- Always apply ‘shuffleboard wax’ to the playing surface before each game, to prevent scratches. Use Silicone spray as an alternative for surface coating.