Frequently Asked Questions
Do you need to be a woodworker to construct a set of Builder Boards?
No, but it sure helps. If you aren’t a woodworker you will need help with tools and pattern layout from an experienced woodworker. Many sets (as I describe in the 3rd Edition) have been built by shop classes and scouts. Also there are about 200 woodworking clubs around the country and many build projects for their community. Volunteers built many of the sets in the approximately 25 children’s museums around the country.
What tools are required to construct a set of Builder Boards?
You will need all the standard hand tools and safety equipment: measuring tape, handsaw, dust masks, eye protection square etc. Power tools: A shaper, (1 hp) is by far the easiest but I have built sets using a 3hp router in a router table with good dust collection.
What sort of materials are necessary and how much do they cost?
I have made sets using marine plywood, big box store plywood and recycled and left over plywood so just about anything can work. If you want to leave the set outside use marine plywood, otherwise interior plywood is fine. Fill all the voids. Make sure all plywood is the same thickness!
How long does it take to construct a set of Builder Boards?
It’s a big project. The steps for each board are: (1) Cut the correct length board from plywood, (2) notch the board, (3) round the edges, (4) sand, (5) seal, (6) sand (7) varnish, (8) sand again (9) final coat of varnish. A CNC will help but not as much as you hope. Finishing is somewhere near half the work.