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I use a 3 1/2" hole saw with a 1/4" pilot on a drill press stand  to cut out the plywood disks.  The plastic/vinyl nipple pad is cut with the same hole saw with a hand held drill motor on some scrap Homasote.

I use a vac on the drill stand to keep the circular cut clean.

IMG_8679

You can see the 3  1/2" scars from cutting the disks on the scrap 2 X 12.

I then insert a large landscape timber nail into the pilot hole and hold the disk  with friction on a router table with a 1/4" round over bit. The disk rartles around somewhat and is a tad nasty but it gets the job done.

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Oh, I didn't think about a hole saw, that's gotta be much faster!  I found my router jig, it goes down to a 1" circle but requires several passes.

Love the drill press dust collection attachment!

@Tom Tee posted:

I use a 3 1/2" hole saw with a 1/4" pilot on a drill press stand  to cut out the plywood disks.  The plastic/vinyl nipple pad is cut with the same hole saw with a hand held drill motor on some scrap Homasote.

I use a vac on the drill stand to keep the circular cut clean.

IMG_8679

You can see the 3  1/2" scars from cutting the disks on the scrap 2 X 12.

I then insert a large landscape timber nail into the pilot hole and hold the disk  with friction on a router table with a 1/4" round over bit. The disk rartles around somewhat and is a tad nasty but it gets the job done.



I recognize those Tom, I can see them from here!

That looks like a similar short loop berber carpet to what is in my finished basement.

For my layout step 1 was building the lift table, step 2 was taking down and crating up an 8' Olhausen pool table (~700lbs) last night. My son wants it so I'll have to find room to store it somewhere. But the lift table is out of the shop and almost in position.

Over the years my sinuses have become more and more sensitive to fine wood particles. I wear a dust mask now even with the dust collection and a filtration unit, every thing 5 microns.  I solved for the most part the worst offender, the chop saw, by building a box almost completely around the saw and sticking a 4" hose from the collector into box. It throws a few shavings but seems to taken care of the really fine stuff. Something fixed in place like Tom's pvc pickup tube would work under my band saw table, another major source of fine particles.

It appears the only joint issues happen to be with the two legs holding the hoist and the wide stretchers between them.  I re-clamped, checked for square and added two, pre-drilled screws through each leg and tenon. All tight again. No more up and down it until I get a couple of benches on either side to help anchor the side tables.

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