DIY Project: homemade Moeller pad

Readers here will remember my first attempt at making a tilted wood practice pad, during the pandemic. It was a rough job, and the tilt was insane, but I learned a lot from the process. A friend named it the Hero Tilt pad.

Not long after finishing that project, I came across this photo of a pad made and used by Sanford “Gus” Moeller.

It was one of the most beautiful pads I’d ever seen, and I wanted to own it.

I also knew that wasn’t likely to happen. This one was either in the hands of Moeller’s descendants, or a collector, or maybe even a museum.

So if I wanted one, I’d have to make my own. The trouble was that I’m not an experienced woodworker. I own no power tools and I wasn’t prepared to lay out a ton of money on the project. So I made a deal with myself and decided that I’d take my time, do my best, and be willing to live with the results.

Part One: I got the wood slabs from a scrap pile at a construction site near my home. 

The cylindrical pieces came from chair crossbeams dumped by a restaurant when they replaced their broken chairs. Unable to get accurate measurements from a photo, I went “by the eye,” as they say. I drew lines for simple cuts with a hand saw, and after the pieces were cut I sanded them all by hand. I mostly wanted to sand down the sharp edges so they wouldn't snag on anything. Since I was working with scrap wood, hand tools and arthritic hands, I was prepared for my pad to be a bit more rough and ready than Moeller’s. 

Part Two: I roughed up the facing edges and used wood glue to attach the three main pieces together. I used a wood stool and bicycle toe straps as clamps to set everything overnight. When the glue dried, I went back and added a couple of wood screws for stability. Then, I added the small side struts with wood glue and let everything dry overnight.

I had thought of staining my pad like Moeller had, but my very rough scraps and glue spots would only be accentuated by stain or vernish. In the end I decided to just paint the wood. I opted for some Gloss Forest Green left over from when we painted our house three years ago. A couple of coats and it didn’t look half bad.

I wanted a name plate, but there wasn’t enough room to apply one where Moeller had placed his, so I mounted it on the side of the base. I made mine from scrap leather and used an art pen. I preserved it with a coat of clear nail polish and mounted it with tiny copper finishing nails.

Part Three: I applied a nonskid bottom using thin mousepad material. I’ve used this on other practice pads and it works well.

Part Four: Finally, I was ready to add the rubber playing surface on top. I marked off the size I wanted, dipped a sharp carpet knife in oil, and cut to desired size. After wiping the oil off, I scored the top of the wood and the bottom of the rubber, applied super glue gel, bound it up with bike toe straps and let dry outside.

Here’s the finished pad, and the original Moeller pad for comparison. It’s not perfect, but it’s solid and feels great to chop on. Considering my lack of woodworking tools and knowledge, I’m still pleased with how it turned out.