Removable Subrail Extensions, Pocket Reducers, pool table

Written by Chris Renson

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To make the 27 degree cut on the board, the easiest way would be to use a table saw. I did not have a table saw available, so I made a paper template, marked the ends of the boards, and cut them on a band saw. I then used a piece of rail rubber to mark the second angle cut, which is only necessary to remove excess wood.

With the angles cut, it is time to glue the rubber to the rail. I taped off all surfaces that I didn't want to glue, then I used 3M-77 contact cement on both glue surfaces. Make sure to stick the rubber to the wood while the glue is tacky. I wrapped the rubber/wood blocks with thick rubber bands while the glue dried. I left them sit for a week, then I removed the rubber bands and tape.

While the rails were drying, I created a template for my pocket cut angles. The quickest way to do so is to take a manila folder, open it up, lay it on top of the rail, line the factory cut edge up with the nose of the cushion, then where the folder overhangs the pocket cut, fold the folder down into the pocket. Make sure you get a good crease. Then you can remove the folder, use a ruler to get a good line in the crease, and then you can cut the template to size. I used CAD software to develop my template, but this method works just as well, and doesn't rely on measurements to be accurate.

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Copyright Notice: This article is written and owned by Chris Renson; Permission must be obtained from the author for reproduction.