[Syuen100]

Hi there,

I am looking to build a 4' x 7’ portable dance floor for Flamenco dancing at home. It may be placed on top of hardwood or laminate. The floor will consist of three layers - a 2mm-thick vinyl dance layer on top, birch or maple plywood underneath, and 3”x3” (1/2” or 3/4” thick) foam blocks underneath (blocks are placed a foot apart to the centre).*

1. For the foam, is it better to use EVA or EPS (Expanded Polystyrene)? Which has better protection from injury as there will be a lot of stamping.
*
2. For the plywood layer, which of the following options will be sturdier on top of the spaced foams?

Option 1: One large piece of 4’x7’ birch or maple plywood that is 3/4” thick.*

Option 2: Two layers of birch or maple plywood, each layer is 3/8” thick. Top layer consists of two 4’x3.5’ plywood. Bottom layer consists of two 2’x7’ plywood.*

If option 2 is better, what’s the best way to connect the pieces of plywood together, *for each of the smaller pieces making up the 4’x7’ layer and between the top and bottom layers?*

Thanks! I’m not handy so I would appreciate explanation in simpler terms.

 

[huesmann]

Option 2 will be far more portable; I suspect you'll need 2 people to relocate Option 1—and a much bigger vehicle to boot.

To connect the two pieces of floor, just use a 4' piece of lumber just a little bit thinner than your foam blocks below the seam. Countersink some screws from the top surface into the lumber.

 

[Syuen100]

Option 2 will be far more portable; I suspect you'll need 2 people to relocate Option 1—and a much bigger vehicle to boot.

To connect the two pieces of floor, just use a 4' piece of lumber just a little bit thinner than your foam blocks below the seam. Countersink some screws from the top surface into the lumber.

Thank you!

How wide should the 4’ lumber be? Can I just have one layer of plywood (connect two 3.5’x4’ of 3/4”-thick plywood), with the 4’ lumber in the middle and the foam blocks one foot apart below the plywood? Instead of having two layers of plywood as described in my original option 2?

Thanks!

 

[3onthetree]

Huesmann is your lead here as he is a "retired ballroom dance competitor and competition organizer!" There are some other threads you might glean a little info or ideas from as well:
https://www.diychatroom.com/659023/
https://www.diychatroom.com/284105/
https://www.diychatroom.com/155103/

 

[Syuen100]

I should have called it floating instead of portable. I don’t plan to move it around, just that it’s not permanently fixed to existing floor.

 

[ron45]

Never done it but seen some dance floors.

How about 3/4" x 12" x 12" parquet flooring put together with dowels with edging.

If its not bouncy enough add foam underneath.

https://www.google.com/search?q=3/4...pAhXhmnIEHfCPBg4Qsxh6BAgNECs&biw=1920&bih=937


https://www.everblockflooring.com/buy-now/everdance-dance-floor

 

[huesmann]

Thank you!

How wide should the 4’ lumber be? Can I just have one layer of plywood (connect two 3.5’x4’ of 3/4”-thick plywood), with the 4’ lumber in the middle and the foam blocks one foot apart below the plywood? Instead of having two layers of plywood as described in my original option 2?

Thanks!

If the floor doesn't truly need to be portable, then a single 4x7 sheet is probably superior than something that needs to be assembled. If you're not going to actually take it anywhere, just need it to be moved around the house, then I'd go with the monolithic construction.

The good ballroom competition floors are typically made from a single sheet of plywood, typically in 4' squares (coz ply comes in 4x8 sheets and it's easy to just cut one in half) and often maple, but you may find it difficult to source maple. They're also typically sprung, with a framework of wooden slats on the bottom to allow most of the surface to have a little bounce (sometimes the floors are set up on concrete floors, which I'm sure you know is hell on your feet for dancing).

In your case, I'd just get a sheet of 3/4" hardwood plywood and cut a foot off one end, sand it down nice (or seal the edges) to avoid future splinters, and glue your foam blocks to the bottom. As far as block spacing, I'd suggest no more than 18-24" between blocks.

 

[Syuen100]

Thanks again Huesmann.

 

[huesmann]

Oh, you may also want a decent polyurethane to finish the surface.

 

[Syuen100]

Hi Huesmann, I have checked the local store for 4’x8’ 3/4”-thick plywood, they only have spruce or fir plywood. The maple or birch plywood is really just aspen interior with maple/birch veneer on both sides. Are these options sturdy enough for dancing on them?

 

[huesmann]

Yeah, I think those would be fine. Get whichever has the smoothest finish on the surface.