Composites Table

This weekend I started building the composites table. I measuered all of my rolls of material (vac bag, Dacron, etc) and had a rough design sketched out. The tricky part about fiberglass is it comes in 50" wide rolls, so normal 4x8 sheet of plywood is not wide enough to cut on. I ordered a 5x10 sheet of 1/8" thick HDPE (high density polyethylene, think cutting board material). 

I ordered 3" casters from Amazon and purchased the rest of the materials from Lowes. 

I started by building the frame for the lower shelf out of 2x4's. The legs were made from 2x4's and 2x6's. 

Next, the frame for the top was made from 2x6's.   Since the 5x6ft top was larger than any commercially available plywood, I had to split the top into two pieces.  

Here's a detailed pic of the joinery between the table top frame and the legs. Nothing fancy, just some solid lap joints held together with screws.

With the top and legs done, it was time to attach the bottom shelf.  The bottom shelf is 1/2" maple plywood.  

3" casters being attached with 2" lag screws. I don't like putting screws into end-grain, but I didn't see a better option.  

Next, we cut the top pices of 3/4" plywood to 3x5' and attached them with countersunk screws.  The overhangs are 3". 

All holes were countersunk for a nice flush fit.