1. Cut plywood sheets to size if not pre-cut: each panel should be 36 x 72 inches to fold into four equal sections (2 panels per half).
2. Sand all plywood panels thoroughly, starting with 120 grit then finishing with 220 grit for a smooth surface.
3. Join two pairs of panels by attaching piano hinges along the long edges using 1-inch wood screws. This will create two halves that fold in two panels each.
4. Attach the two halves together along the center fold using piano hinges, so the entire tabletop folds into four sections.
5. Fill any screw holes or imperfections with wood filler, let dry, then sand smooth.
6. Apply painter's tape to mark the boundary lines for the white lines on the playing surface.
7. Paint the entire surface green or blue using acrylic paint. Allow to dry completely.
8. Paint the white lines for the table tennis markings carefully using white acrylic paint. Let dry.
9. Apply 2-3 coats of clear polyurethane finish to protect the painted surface, allowing each coat to dry fully and lightly sanding between coats.
10. Install the table tennis net and posts according to the manufacturer’s instructions.
11. Let the table dry for 24 hours before use.
12. To store, fold the table into four sections for compactness.
Additional tips:
- Use clamps to hold panels steady while screwing hinges.
- Ensure hinges are aligned perfectly for smooth folding.
- Check the flatness of the table after assembly; use shims if needed to level.
- Consider adding rubber bumpers on edges to prevent damage during folding and movement.