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.

Click for larger image


2) Stack, glue, and clamp them together.

Click for larger image


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.

Click for larger image


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).

Click for larger image


5) Center the guide, mark the edges and remove it. Transfer the lines to both the top and bottom of the block.

Click for larger image


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)
 
Click for larger image


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.

Click for larger image


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).

Click for larger image


9) Saw the brick in half, splitting the holes down the middle.

Click for larger image


10) Open up the block and glue and clamp it together "book page" style.

Click for larger image


11) After the glue dries use a belt sander to level the bottom surface.

Click for larger image


12) Use a 1-1/2" drum sander to smooth out the grooves then level out the ridges with a palm sander.

Click for larger image


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.

Click for larger image


14) Trim to width (in this case 11-1/2").leaving an equal amount of ridge on each side.

Click for larger image


15) Square up the bottom of the tray.

Click for larger image


16) Set the width to 5 and square up the top.

Click for larger image
 

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".

Click for larger image


18) Fill with chips and enjoy! (box will hold approximately 250 chips)

2006, Jeffrey P. LaForge, All Rights Reserved