I am building a train table for my young daughter, intended to also double as a play table with storage bins underneath. The overall design seeks to avoid any sharp corners. I am nearing completion, but have run into a problem with my initial design, and am looking for input and ideas. I think I need to brace the legs and reduce the end panel weight.This is the current state of the project. The end panels are not yet fastened to the rails. The 5' x 3.5 ' x 3/4" plywood table surface is already cut, and is intended to be removable. Additional supports for the table top will be included (noted in the picture below).Table set in place, ends are not fastened to rails.The rails are 5/4 x 4 inch, with 2x2 supporting the surface.Ends of the rails.I originally planned to use lag bolts to hold the rails. The 2x4's would support the rail ends to avoid sheer force on the lag bolts.End panels with 2x4's for rail support.My problem is two-fold. First, I am afraid that lag bolts put into the ends of the rails will split the rails if any side or twisting force is applied (likely with kids). The lag bolts I bought are possible too large, and the rails, even with end support, don't seem likely to be strong enough for this kind of force. I am also concerned this design would break when I inevitably have to move it up and down stairs or corners.Scrap piece of 5/4x4 and my 5/16's lag bolt. The rails are the same size as the scrap.In addition to the weakness of the rail-to-end panel joint, I am concerned the end panels themselves are going to be too heavy. The panels are 18"x4', also 3/4 plywood, and each end weighs about 15 lbs.My currently plotted new approach is to use angle brackets to provide additional support. I would also use smaller lag bolts (or maybe just 3" deck screws) to connect the rails.https://ift.tt/2T98NTQ reduce the weight of the end panels, I am considering several options. I could simply cut out the center for a square/rounded window, cut some fun circles, cut clear to the bottom edge, or something else.Possible weight-reduction end panel cuts.Thus I am looking for advice on ways to brace the frame and reduce weight. Any other thoughts on the project are appreciated.More project images - https://ift.tt/2ICRo1I. via /r/DIY https://ift.tt/2SWy8Bq
