Poker Chip Tray
Please note that my initial tray size was 11-1/2" x 6", but I found that 11-1/2" x 5" would be a better fit for an octagonal table. The pictures in steps 1-16 show how I made the initial 6" tray but the dimensions stated in the picture would be for a 5" tray, so the numbers in the descriptions may be different that what shows in the pictures. Use the typed descriptions for actual measurements.
1) For 8 trays you will need 2 pieces of 6"x8' - 3/4" stock. Rip each board to
2-5/8". You will need 4 pieces 11-15/16" long for each tray.
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2) Stack, glue, and clamp them together.
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3) Create a guide approximately 11" x 2-1/2" with 7 holes centered on the guide. The
holes should be exactly 1-5/8" on center.
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4) Plane the glued sides of the block smooth and center the guide on a planed side. (My drill press would only
drill half way through the block so I need to drill from both sides).
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5) Center the guide, mark the edges and remove it. Transfer the lines to both
the top and bottom of the block.
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6) On both the top and the bottom, find the center vertically. Then center the
guide vertically and horizontally and mark the holes to be drilled. (Use the
lines you transferred in the previous step to center the guide horizontally)
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7) Using a 1-1/2" Forstner bit, carefully drill half way through each side of
the block, forming a hole that goes completely through the block.
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8) Trim the block down to 2" wide with the holes centered. Be sure to mark the
block so you can match it up "book page" style later (note the "B" in the top
left and top right).
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9) Saw the brick in half, splitting the holes down the middle.
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10) Open up the block and glue and clamp it together "book page" style.
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11) After the glue dries use a belt sander to level the bottom surface.
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12) Use a 1-1/2" drum sander to smooth out the grooves then level out the ridges
with a palm sander.
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13) For the chips to sit
nicely while playing, you will need to tilt the tray slightly towards the
player. If you plan to use the box for storage only, skip this step. Glue
spacers 1/2"x3/16"x12" to the bottom of the tray 4-1/2" from the base of the
tray closer to the player.
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14) Trim to width (in this case 11-1/2").leaving an equal amount of ridge on
each side.
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15) Square up the bottom of
the tray.
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16) Set the width to 5” and square up the top.
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17)
Using the tray as guide, make a box out of 1/2" stock 2-1/8" high. To allow for
a top on the box, put a 1/4"x1/4" rabbet in the sides (along the top) before
assembly. If you do not plan to use a top, cut the 1/2" stock to 1-7/8" instead
of 2‑1/8".
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18) Fill with chips and enjoy! (box will hold approximately 250 chips)
© 2006, Jeffrey P. LaForge, All Rights Reserved