How to Replace Coffee Tray Damaged Bottom with White Hardboard - Part 1 of 2 - Board Preparation

Husky X-Workhorse 
Workbench Fold away

By Gary Boutin 

Supplies and Tools:  
Dry Erase Fine Point Marker
Fat-max 25 ft. Tape Measure
Husky X-Workhorse Workbench
Ryobi 7-1/4-Inch Circular Saw 
Spring Clamps (2)
Yellow Square  
White Hardboard

The coffee cup series was written in April 2014 showing how to treat a new hardwood coffee tray into service and long lasting wear. The coffee tray was redone in October 2014 because the bottom board started to be removed by the coffee cups being stored after use.  The project did not quite fail because it lasted six months before it needed to be re-worked. 

This post is a shows the nine steps to prepare for the replacement of the bottom board with a new board without destroying the wood coffee tray. Because of the length this post has been broken into two parts.

Step 1: Fig.1 shows the Ryobi 7-1/4-Inch Circular Saw used to cut the whiteboard that will be placed inside the tray.  

Fig.1 Circular Saw

Step 2: Fig.2 shows the damaged coffee tray with its condiments.

Fig.2 Damaged coffee tray

Step 3: Fig.3 shows the damage done to the top of the coffee tray.

Fig.3 The Damage

Step 4: Fig.4 shows the Husky X-Workhorse Workbench that is flat when stored but opens up to a table when placed together.

Fig.4 Workbench

Step 5: Fig.5 shows a tape measure to measure the inside of the coffee tray.

Fig.5 Fat Max Measurement Tape

Step 6: Fig.6 and fig.7 shows the tape measure checking the length and the width of the coffee tray.

Fig.6 Length

Fig.7 Width

Step 7: Fig.8 shows that all plans should begin with some thought, below are the thoughts of this project. These thoughts then begin the plans of the project.

Fig.8 plans inside coffee tray

Step 8: Fig.9 shows the white hardboard laying on top of the workbench.

Fig.9 White hardboard

Step 9: Fig.10 and fig.11 shows that a yellow square is placed near the edge of the whiteboard for a squared cut. A line was drawn using a dry erase fine point marker.

Fig.10 Square Right side

Fig.11 Left side square

How to Replace the Coffee Tray Damaged Bottom with White Hardboard:

• Part 1 of 2 - Board Preparation
• Part 2 of 2 - Inside Board Replaced

How to Seal a Coffee Tray

• Part 1 of 6 - Washing
• Part 2 of 6 - Oil Seal Coat
• Part 3 of 6 - Apply Polyurethane to Tray Bottom
• Part 4 of 6 - Sealing The Top
• Part 5 of 6 - Cleaning The Tool
• Part 6 of 6 - The Finish Product

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