I've been using this table for about 5 years now. The idea was inspired by the TI article about a 4' round table from one 4x8' sheet of plywood. Mine uses a 4x6' sheet, producing a 2x4' rectangle. It works a bit better for transport in smaller cars than the 4' round does - in my Geo you just flop down the back seats, and feed the parts through the hole. Total dimensions disassembled are 2' x 4' x 1-1/2" - totally flat, park it on the bottom of the pile in your car.

Materials:

• A 4' x 6' piece of 1/2" plywood, or three 2x4' panels. You can use heavier plywood, but the half-inch will hold my weight.
• The finish of your choice. I just sprayed mine with several coats of polyurethane.

• A jigsaw or sabre saw, with a couple of fine wood-cutting blades. Expect to break a few.
• A sanding block with coarse sandpaper, and/or a rasp.
• A tape measure, a straightedge, and a square.
• A piece of string for drawing curves.
• A pencil.

1. ENDS:

• Cut 4-foot by 6-inch strips from the edge of two panels, then an 18-inch square from the end of each, leaving a pair of 18" x 30" pieces (figure 1).
• Measure the thickness of your top. Nominal 1/2" plywood ain't 1/2" thick, it can run from 3/8" to 7/16". Call your result x. Draw a line across an 18x30 piece x inches in from one end (figure 2a).
• Find the center of that end. Measure outward 2-1/2" to each side and mark. Go 6" further on each side, and mark. This should leave you with a 1/2" gap, a mark, 6", a mark, 5", a mark, then another 6" - mark - 1/2" (figure 2b).
• Cut away the 5" and the two 1/2" areas, leaving a pair of 6" wide tabs, of depth x (also figure 2b).
• Next, cut a slot 3" deep along the centerline, x wide (figure 2c). In the middle of the piece, make a 6" by x vertical slot (also figure 2c).

• Use your string and pencil to draw arcs as shown in figure 2d. Cut 'em out.
• Sand all cuts smooth.

1. CROSSPIECES:

• Round the ends of the two 4' x 6" pieces as shown in figure 3a.
• Measuring 6 inches in from each end, cut a pair of 3 by x inch slots (figure 3b).
• Sand edges and cuts.

1. TOP:

• Measure in 6" from each end, and draw a line across the 2 x4" top. Draw another line x inches inward from each of the first two. (figure 4).
• Find and draw the centerline. From there, measure out 2-1/2" to either side, in the x-width strips. Mark there, then mark again 6" out toward each edge.
• Cut out the resulting slots, which should fit the tabs you cut back in step 1. Double-check this before you cut anything.
• Sand all edges and cuts.

1. FINISHING TOUCHES:

• Stain if you want.
• Spray or brush on several coats of a hard finish like polyurethane. You'll want this table to stand some abuse without damage.
• Use the 18" pieces to make whatever you'd like - maybe chess / checkers / tablero / go boards.