Alright, buckle up, because I’m about to walk you through my weekend project: crafting a portable wooden flooring solution for my rubber volleyball setup. Yeah, sounds a bit out there, but trust me, it was a fun challenge!

So, it all started with the need for a better surface to play volleyball on. Our backyard is mostly grass, which gets chewed up pretty quickly, especially after a good rain. I wanted something that would offer better traction, be easier to clean, and, most importantly, be portable so I could move it around or even take it to a friend’s place.

Phase 1: The Brainstorm & Materials

• First, I sketched out some designs. I knew I wanted interlocking sections for easy assembly and disassembly.
• Next, I hit up my local lumber yard. I decided on using hevea wood (rubberwood) because it’s relatively inexpensive, durable, and has a nice, smooth surface.
• I bought enough hevea planks to cover about 10×10 feet. I also grabbed some wood screws, wood glue, and some outdoor sealant.

Phase 2: Cutting & Preparing the Planks

This was the tedious part. I spent a good chunk of Saturday morning measuring and cutting the hevea planks into smaller, manageable squares. I used a circular saw for the straight cuts and a jigsaw for the interlocking edges. Let me tell you, cutting those interlocking shapes was a pain! I definitely messed up a few pieces and had to recut them. Measure twice, cut once, folks!

After cutting, I sanded down all the edges to prevent splinters. Nobody wants a volleyball game interrupted by a rogue piece of wood!

Phase 3: Assembling the Sections

I decided to create four separate sections, each about 5×5 feet, to make them easier to carry. I used wood glue and screws to attach the smaller hevea squares to a supporting frame made of thinner hevea strips. Clamping everything together while the glue dried was crucial to ensure a strong bond.

Phase 4: The Interlocking Mechanism

This was the trickiest part. I wanted a simple, robust interlocking system. I ended up using a combination of overlapping edges and metal brackets. On one side of each section, I created an overhanging edge, and on the adjacent side, a recessed area for the overhanging edge to fit into. I then secured the sections together with small metal brackets and screws. It wasn’t perfect, but it got the job done!

Phase 5: Sealing & Finishing

To protect the wood from the elements, I applied several coats of outdoor sealant. This took a while, as I had to let each coat dry completely before applying the next. I also added some non-slip pads to the bottom of each section to prevent them from sliding around on the grass or patio.

The Grand Reveal & Lessons Learned

Finally, on Sunday afternoon, I assembled the portable wooden flooring in the backyard. It wasn’t perfect. Some of the sections didn’t align perfectly, and the interlocking mechanism was a bit clunky. BUT, it was functional! It provided a much better playing surface than the bare grass, and it was surprisingly sturdy.

Here’s what I learned:

• Accurate measurements are KEY. Seriously, double and triple-check everything.
• Cutting interlocking shapes with a jigsaw is hard. Maybe consider using a router next time.
• Outdoor sealant is your friend. Don’t skimp on it.
• Patience is a virtue. This project took longer than I expected.

Overall, it was a satisfying project. I now have a portable volleyball court that I can use in my backyard or take to the park. It’s not perfect, but it’s mine, and it’s a heck of a lot better than playing on uneven grass!