DIY Network

Puzzle Piece Dance Floor A unique dance floor is created. From "From Junky to Funky" episode DFJF-310

In this segment, host Samantha Gleisten uses a wooden table top and paint to create a unique dance floor.

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Materials:

thrift store tables
tongue and groove plywood
1x3 oak
rounded oak trim
scrap wood
masking tape
stain
primer
paint
gloss polyurethane
1" screws
circular saw
table saw
chop saw
jigsaw
band saw
"T" square
power drill
paint brush/roller

	Figure A
	Figure B
	Figure C

1. Make a puzzle piece joint template from scrap wood, and then cut it out using a band saw.

2. Put masking tape over the sections where you will be cutting to protect the wood surface. Measure and mark where each puzzle piece will go on the corresponding taped table tops (figure A).

3. Detach the legs from the table tops.

4. Make the long straight cuts using a circular saw being certain to stay toward the outside of the line markings.

5. Cut out the puzzle joints with a jigsaw (figure B).

6. Assemble the pieces on top of two sheets of 4' x 8' tongue and groove plywood, creating an 8' x 8' work surface.

7. Measure the dimensions of the puzzle piece floor and cut 1 x 3 oak boards to border the outside edge of the puzzle piece floor. Use a chop saw to make the cuts, using 45-degree angles for the corners.

8. Layout the border (figure C), and then mark the plywood sub-floor with the new outside dimensions.

9. Cut the plywood sub-floor to the marked dimensions using a table saw.

10. Pre-drill with a countersink up through the bottom of the sub-floor about 1-1/2 inches in from the edge every two feet.

11. Put the puzzle pieces in place. For any thin table top piece, cut strips of scrap wood and glue them to the underside, raising them up to fit flush with the rest of the pieces.

12. Measure and cut rounded oak trim to run around the outside edge of the plywood ends. Make the cuts with a chop saw and again use 45-degree angles for the corners.

13. Stain all the unfinished wood pieces, and then touch up anything that needs work. Prime and paint any puzzle pieces that aren't stainable.

14. Apply many coats of gloss polyurethane to all the pieces, creating a smooth-durable surface.

15. Attach the rounded trim to the sides of the plywood sub-floor with a nail gun. Attach the 1 x 3 border with one inch screws through the pre-drilled holes.

Project Cost:

Table tops: $75
Wood: $32
Materials: $24

Total: $131

RESOURCES :

The Brown Elephant
Website: www.howardbrown.org/hb_brownelephant.asp