1) This piece will be the base of you rail. Make sure the ply is topside up. I chose a 4” rail, so using the same centre nail; I measured 20” (or 4” from the outside edge) and traced the inner arc. Repeat on the second edge. Connect the two semi-circles with a straight edge. Before you cut, double-check your rail width with a yardstick to check for uniformity. Measure twice, cut once!
2) Using a drill bit approximately the same width as your jigsaw blade, drill a series of holes just big enough to fit the blade. You may want to ask someone to hold the cut portion when you get about half way through the cut to avoid breakage. If you are running solo, you can use clamps to secure the cut portion. Make the cut.
3) Now you need to cut the lip of the rail. Again, make sure the ply is topside up. This piece has been traced from the original (now the 4” rail oval) to ensure a snug fit. With the other piece of plywood (the uncut oval), create a jig for your arch 1 ½ “ from the outer edge of the ply. Repeat the same process as in step 2, creating a 1 ½” ring for the lip. Mark this top and bottom.
4) The 4” rail and 1 ½” lip should have the same circumference. Double check the fit by laying the three pieces together. Using wood glue, glue the top of the 1 ½” lip to the bottom of the 4” base rail. Secure together with 1 ¼” screws.
5) Place the ¼” veneer sanded side up on your cutting surface. This will be the start of the racetrack. Place the base oval piece top up on top of the ¼” veneer. Trace the solid oval onto the veneer with a pencil.
6) Using masking tape, tape over the line you just traced. Press the tape down hard (I suggest 3M painters tape for risk free removal). This is to avoid splintering.
7) Repeat step one, tracing over the tape with a black marker. Make the cut.
8) Place the rail over both the base and veneer to ensure a proper fit.
9) Using a drill bit the size of your bolts (or T-nuts) drill holes 1 ¼” from the inside of the 4” rail. I used 3 on each arc and 3 on the flat rail portions. This is to secure your rail to the table.
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