Okay so here’s the deal, my knees and ankles were screaming after playing volleyball on concrete all summer. Seriously, that stuff is brutal. Woke up feeling like I got hit by a truck. Needed some kind of floor that actually gave a little, you know? Shock absorption was the big goal.

First Try: Just Wood Over Stuff

Started simple because why not? Grabbed some leftover plywood panels I had kicking around. Slapped them right down on the driveway where we usually play. Felt like… well, like plywood on concrete. Maybe a teeny bit less harsh when landing? Not really though. Still jarring. Plus, the ball bounced funny as heck.

Figured it needed more structure underneath. Rummaged through the garage. Found some foam packing sheets, those big squares that come with appliances. Thought “Perfect! Soft!” Laid the plywood down on top of those foam squares.

Jumped on it. Crunch. The foam completely squished flat underneath me. No give left at all. Felt dumb for about five seconds before realizing foam needs support too. Wasn’t just gonna lay down on concrete and not pancake.

Bringing In The Hard Maple

Remembered seeing this super tough wood called hard maple used for basketball courts and stuff. Sounded perfect. Pricey, but needed something strong. Ordered a couple of planks.

Planning Phase (Sort Of):

• Wanted small portable panels we could carry out and set up.
• Each panel needed framing underneath for the foam.
• Connections had to be quick and simple.

Bought:

• Hard maple planks (not a full floor, just for the surface)
• Regular pine boards for the frame
• High-density foam rolls
• Wood glue, screws, hooks, eyes.

Building Panel One: The Heavy Brick

Measured and cut the pine boards to make a simple rectangle frame. Laid the high-density foam inside the frame, cutting it to fit snug. Then glued and screwed the hard maple planks across the top to seal it all in. Made one solid panel.

Problem: This thing weighed a ton! Seriously hard to move. Carried it outside, dropped it on the driveway. Jumped. Much better than before! The foam compressed just a little, taking the edge off the landing. Maple felt solid underfoot, good bounce for the ball. But man, that weight! Building several of these? No way. Needed lighter or easier to move.

Building Panel Two: Let’s Try Lighter… Too Lighter.

Tried making the frame thinner to shed weight. Used cheaper, lighter wood. Also bought thinner foam to save space and maybe weight. Same process: frame, glue/screw foam in place, slap maple on top.

Bigger Problem: Jumped on it… and felt the whole panel flex like crazy under me. That thin foam compressed way too easily, and the weak frame felt bendy. No confidence at all stepping near the edge. Felt like it might snap. Worse, when you jumped near the center, the whole panel sort of tipped or rocked because the frame wasn’t stiff enough. Useless. Scrapped that idea.

Finally Getting Portable Right

Back to the drawing board. Needed the strong maple top, good foam, sturdy frame… but figured out portability was about size and handles, not just making everything flimsier.

• Made each panel smaller – about 3ft x 3ft max.
• Used decently strong pine for the frame again, but kept it simple.
• Used the thicker, high-density foam again.
• Attached sturdy handles to the sides.
• Put simple hook-and-eye latches on the edges so the panels clip together.

Built four panels this way. Stored flat stacked in the garage. Takes about two minutes to carry them outside to the driveway, clip them together. Voila! Instant volleyball floor about 6ft x 6ft.

How Does It Play? Heck Yes!

That hard maple surface is tough as nails. The ball bounces true and fast. Digging feels solid. But landing? That’s the magic. Jump and spike, land on your feet… you feel the give. It’s not squishy, it’s like the floor just takes a little bite out of the impact. Knees and ankles thank you later. Still playing on the concrete edges sucks, so we try to stay inside the wood zone. Totally worth the sweat and figuring it out.

Honestly, figuring out the thickness and size took some trial and error. Almost gave up after the bendy panel disaster. But now? Packing it up after a game, my back feels a million times better than it did playing on straight concrete last year. Shoulda done this sooner.