Getting Started with the Volleyball Floor Project
So I’ve been wanting a volleyball court in my backyard for ages but didn’t want anything permanent. That’s how the whole “removable plywood flooring” idea popped into my head. Went down to the hardware store last Tuesday and grabbed eight 4×8 plywood sheets – chose the half-inch thick ones because they seemed sturdy enough but not crazy heavy.
Prepping the Materials
First thing, laid all sheets on the driveway to check for warping. Found two slightly bent ones and swapped them at the store. Measured our court area and realized we needed exactly six panels for the playing surface plus two extras for replacements. Grabbed my circular saw and ripped them all down to 4×6 foot pieces – standard volleyball dimensions, you know?
Tools Used:
- Measuring tape (must’ve checked 20 times!)
- Circular saw with plywood blade
- Power drill
- Router for smoothing edges
- Wood glue
The Assembly Puzzle
Here’s where it got interesting. Made tongue-and-groove joints on all four sides of each panel using my router. Took three practice scraps to get the depth just right – too shallow wouldn’t lock, too deep made the plywood weak. Applied wood glue into the grooves before connecting each piece, then drilled pilot holes every foot along the joints and screwed them together with heavy-duty deck screws.
Dropped my cordless drill twice during this part – nearly had a heart attack! Once all connected, the real test was walking across the joints. No wobble, no creaking! Sanded the whole surface for two hours with 80-grit paper to prevent splinters.
Making It Removable
This was the tricky part. Instead of permanent fasteners, used those door bolt latches you see on gates. Installed three sets per panel connection – one on each end and one in middle. Took some fiddling to align perfectly but now they slide apart like butter. Applied weatherproofing stain after assembly since UV protection matters even for temporary setups.
Final Outcome
Got the neighborhood kids to help carry panels to the backyard (promised them first game rights!). Took us 20 minutes to snap all panels together on the grass. First volleyball hit the surface – beautiful solid “thump” sound, no dead spots. After playing, unsnapped everything and stacked panels vertically in the garage shed. Best part? Total cost was under $120 since plywood was on sale!
