-hendrik (used to be tweaks_rock_me)
"Over time, most people experience life involving love, suffering, compassion and an unspeakable drive for something new...For me there's skiing, nothing more nothing less and it encompasses everything, everyday I'm out there."
- Pep Fujas
what ever you get make it bendable so you can curve it over the edges and screw it in the sides... or make the box hollow get a thick enough material for the top and put some screws in through it but not so they stick out dunno if that will eventually losen but the first way wont
This is easy. First for the surface use HDPE or UHMW. UHMW works better but costs more. Second use PVC as coping and make sure its perfectly level on the sides. I would drill into the top. You won't catch. And last when you drill the surface into the wood use a Counter-Sink bit.
synthetic decking, or go to a warehouse and see if you can find a plastic palet
they're made of a seriously non reactive plastic that has teflon in it that will repel solvents, and also slides like lexan, you can cut it up and fit it together, although its got 3x3 inch holes in it, they wont effect it at all
it dosen't have to be too thick, i know lots of professional builders that build boxes for local ski areas in MI use UHMW and its usually inbetween a quarter and half inch thick. and its super durable and slides well too.
Google ^ . Not cheap though. Around $70 for a 4 x 8 sheet. Been said but white PVC is a great inexpensive solution. Get a bunch of like 1 in od pvc sticks that are as long as you want your rail. They'll prob cost you less than $3 a piece.
Easiest way to build the the top is to get Liquid Nails in Caulk Tube. Run a bead down your PVC and then stick it to your wood surface. Repeat until the whole surface is covered. Let it set and then add screws from the bottom side for added grip. I would then run another bead in the crack between your PVC sticks. That should be pretty much bomb proof.