Thats how you and I would do it. However a lot of plywood users are people that don’t have that ability or interest in the carpentry end of things and that’s why they go with a basic sheet of plywood in the first place. I have people come over and get me to cut up things for them and they are terrified of my power tools.
A 5’ x 10’ sheet is certainly more $ than a 4’ x 8’ sheet but not a lot. My jaw has dropped at the money some have spent on custom made benchwork, so spending a few bucks on a custom sheet of plywood wouldn’t seem unreasonable if that’s what they wanted.
Since none of us can seem to find any place that would sell a 5X9 sheet, it would be interesting to know your point of reference concerning price. What are you comparing?
I would agree that the plywood manufacturers probably have the ability to change sizes, but how many sheets are you willing to order? One? A hundred? A thousand? I doubt very much that the local lumber store is going to be interested in special ordering one 5X9 piece. Maybe a big sign shop actually has access to the stuff, but that guy isn’t going to run a piece of plywood through his books at cost either.
I’m assuming we are talking about modelers who are not capable of sawing, gluing and screwing plywood sheets together?
There are specailty plywood suppliers that will stock or order sizes larger than the traditional 4x8. Generally used for signs, specialty substrate on casework, store fixtures and tops. Not all species are available in larger panels. If one was to need a panel so large for our purposes, a search will show suppliers, but usually in larger cities or manufacturing areas.
I use one of these suppliers for cabinet grade, and flexible panels in various wood species.
http://www.boulterplywood.com/
The first Google search showed this:
The big box lumber/hardware stores near where I live will cut it for you. At least one cut is free, I have never asked for more. Makes it esaier to haul home.
Enjoy
Paul
My local big box suppliers do a brisk trade in 2 x 4 sheets of (mostly) thinner plywood. I guess the amateur cabinetmakers around here specialize in night stands and other small items.
I recall some years back MR suggested cutting a triangle off a 4 x 8 sheet and reattaching it to make a shed-shaped surface for one track plan. That was back when there were several suggested plans in each issue (and, boy, did I just date myself!)
Since my construction sequence has me making cardboard track pattern templates first I have no problem with using small or odd-shaped pieces of ply when I cut my cookies. I just make sure to keep everything properly aligned. OTOH, I’ve reached the point in physical capability where handling even a 4 x 8 sheet of plywood is more of a challenge than I need. 4 X 8 foam, no problem (yet.)
Chuck (Modeling Central Japan in September, 1964)
I have two specialty plywood places about fifteen minutes away from my house where you can go buy larger sheets as singles. I have not been there in a long time but when you own a pick-up truck you have a lot of best friends all of a sudden.[(-D] Anyway my friend was buying a 5’ x 10’ sheet of birch ( i think it was Birch) It’s what they make slate billiards tables with, so I was told. The price of the 5’ x 10’ was about 60% more than the 4’ x 8’. The price difference (%) was the same for all grades, only the $ amount changed depending on the grade. For some the price difference may be an issue, for others maybe not. Someone might prefer paying for a larger sheet over the thought of mating up two smaller pieces. Also the price of lumber goes up and down like the price of gas so it’s a crap shoot.
I recall seeing sizes larger than 4x8’, but that was when I was a kid, over 50 years ago.
Of course what matters is present day. 50 years ago is only good if you have a time machine.
BTW, I’ve noticed at Home Depot and Lowes, the 4x8 sheets of plywood are pretty warped. I decided to us OSB (Oriented Strand Board) nominally 1/2 inch thick as it has little or no warp and only costs about $8 at my local home depot.
Pics of larger sheets on Bobs’ link. Thanks for posting Bob.
Yeah, that sheathing grade stuff can be warped - just have to be picky about what you buy. Or you can buy the better stuff they have for more money. I’m not a fan of OSB, but I’m sure it works for a tabletop layout.
Enjoy
Paul
I worked in a commercial lumber yard in high school back in the dark ages and remember only 4x8 sheets of plywood. Forward many years and while working with Habitat for Humanity building in Connecticut our local affiliate came into a trailer load of 4x9 sheets of 1/2 inch plywood that had been used to board in an outdoor concert venue. It was nice stuff for sheeting houses as it covered the the rim joist plus the entire first floor wall frame. It would have been nice for model railroading for 9 or 18 ft benchwork.
As noted drywall routinely comes in 4x12 lenghts as it makes it possible to do many rooms with no butt seams and only the middle tappered seam at the 4 ft level. The tappered seam is much easier to finish compared to a butt seam.