BJJ Mats, How to Build - WITH POOL NOODLES!

In this video you will learn how to build a sprung floor for a BJJ Gym or dance studio using pool noodles and plywood. Details of the company that supplied the mats and all the tools required for the project are listed below -
Mat supply - dollamur.com/
TOOLS FOR THIS PROJECT BELOW -
BOSCH Gliding Miter saw - amzn.to/1YTWmn0
Bosch Cordless Circular Saw - amzn.to/1WvS9Vm
Makita Collated Screw Gun - amzn.to/1SaFb0g
Bosch SDS Hammer Drill - amzn.to/1TPR7Vb
Plastic Packers / Shims - amzn.to/1GVIFeL
Silicone gun - amzn.to/16FlxpF
Hammer - amzn.to/1QXfwbf​
Tape Measure - amzn.to/1NIY2sY​
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Thanks Guys, any questions please leave them in the comments below.
Cheers, James.

[@anthonyschweighardt2546]

Hi! What kind of plywood did you use? Birch, maple?

[@deanpirrie97]

Amazing vid, could you use obs board instead of ply?

[@PatrickPrejusa]

thank you for this

[@themovinganna1948]

do you think high-density foam tiles under one layer of plywood would achieve the same effect? Looking to do this for a ballet and pointe studio

[@OurBuild]

Not sure, best way would be to grab a couple of pieces and do a test.

[@afnanbogey]

Might be building a gym soon. This has been incredibly useful mate, cheers 🍻

[@OurBuild]

Glad it was helpful mate 👍

[@Nadnad6996]

Aren’t you defeating the purpose of a uniformed sprung floor by attaching the perimeter of the plywood a solid border?

[@OurBuild]

Not really.

[@themovinganna1948]

Also curious about how long would the pool noodles last

[@IWNTYU]

They last forever because they are like memory foam

[@dwaino86]

Nice one James. My gym also has a sprung floor. It was done almost the same, except instead of pool noodles, coach put dense foam cubes (like jigsaw mat material) under the ply. Also i think he only has one layer of ply.

[@OurBuild]

Thanks Dwain. Sounds like a good combination as well 👍

[@phys1c]

Beautiful build man. Well thought out and executed

[@myrtonen]

4:52 at first I thought you said "a 5 mm pecker". I would consider cutting the noodles probably 5 mm overlenght so they would have some compression to begin with?

[@cmckinnon]

Any learnings or changes you'd make after 2 years?

[@pennieconnell7028]

To save on costs could I use 9mm boards for children's dance studio? Or does that cause other issues.

[@danielduggan6042]

Great build! Could you let me know how you feel about it now that you have used it for a few months? Is there enough spring? Too much? What would you change? Thanks!

[@orlandorymer2507]

Looks amazing thank you! Oosss

[@majidsuleiman6117]

Excellent, informative video! Question for you, can this be done over thin, commercial grade carpet?

[@andrewhoulihan7940]

Hi there. Brilliant video. Can i ask a simple question? I’m a carpenter based here in Ireland 🇮🇪 I’m building a Irish dance studio for my daughters and I’ve come across this pool noodle idea for the floors. If i cut the noodles at 35mm would that work as as you have done here ? I know this floor is for wrestling as you said at the start I’m afraid ill make the floor to springy if you get me. I just want to get it right the first time round!! Love from Ireland 🇮🇪 Andrew

[@OurBuild]

Yeah that would work, but I think a trial run one one board would be your best bet.

[@alvarocornejo6862]

Amazing job! What was the budget for this? how many m2?

[@ronwhite1273]

I've just noticed that guys cut the mats flush on the wall edge instead of staring from the wall and shaving the foam from the frame edge then folding the cover under for better aesthetics and protection, seeing the foam exposed doesn't sit well with my OCD. Thank you for the pointers on edge support as well as 5mm gap in between sheets.

[@jcminvestments9078]

Beautiful, so amazing, I will get this project done soon, thank You so much, happy holidays.

[@xxxband4077]

wicked! i’m away to look at a job like this on saturday. i will suggest pool noodles. did you leave 5mm at the perimeter too?

[@OurBuild]

Nice 🤙 Yeah mate 5mm all round.

[@gregprobyn5980]

Great video, really informative. How big was the floor and what was the approximate cost? I'd love to do this for my place. I look forward to hearing from you.

[@coreyelias4908]

Great video James. How far apart did you space the screws? And were the screws only along the edges of each board?

[@OurBuild]

Cheers Corey, screws about every 300mm. some screws in the middle as well to pick up the joints of the sheets below.

[@alainduchesne9750]

Screws will come out from plywood over time. It’s better to join the 2 layers with velcro. Also, pool noodles foam is very cheap, it will last long.

[@sirpibble]

Nice looking space, good idea with the pool noodles to cut cost

[@Ben-lo5dd]

Hey great stuff. Can I ask what brand silicon you used?

[@brentonchong6694]

Sorry, Maybe a silly question. But what kind of plywood. Quick check of Bunnings and there is various styles?

[@masterlessbjj1486]

Hi, would like to know more less how many times did it take to build this mat with your team and how much square meters is the mat space. Thanks, love your work💪

[@aloneinanearthship4010]

Great job!

[@RoseBrosHTX]

Amazing thank you 🙏🏼 for sharing.

[@ivetteramirez4834]

Hello! These Videos have given me so much insight on flooring that I want to do. I have a question because I do Latin dance instruction and NEED wood flooring. I want to do smooth plywood top. Any suggestions? Would these work without nails or screws? If not then would I glue them? Someone please help. THANK YOU in advance.

[@birakov]

Where do I get the pool noodles please. Awesome gym

[@amtad9786]

Thank you for sharing! You just gave me a big push forward 🤙.

[@mickeynotmouse]

probably a lot less bounce than springs, which I imagine is preferable when you're rolling instead of tumbling

[@mmichels]

Thank you for sharing !

[@doitbeforeyouareready6864]

What would be a good alternative to plywood? Is there some kind of plastic material that would work well? I'm in the Philippines where termites are a big problem.

[@LeoValencia-zo6pt]

Get action systems air cushions made for basketball courts

[@jeremyd2003]

Just buy 2 inch AK wrestling mats.

[@Joez86]

Great video.

[@IWNTYU]

Was it, 1/2 , 1/4, or 5/8 plywood?

[@MissTeeFied]

How costly was this to do (not including the mats) thinking of it for a dance studio.

[@raycarrillo8232]

Great video! Thanks for taking the time to make it and share it! Now that you have used these mats for a couple of years, have you noticed any breakdown whatsoever? I am considering buying the foam blocks from fuji, but your video got my curious. Looking back, would you hand done anything differently? Thank you again for sharing. 🤙

[@OurBuild]

Cheers mate, nope still as good as the day they went down. Only thing id change is leaving a gap around the top mats around all edges for expansion as they stretch.

[@insidiousmaximus]

love a bit of rub n squeak

[@wilkinsoncarpentry6278]

That’s a cool video mate, thanks for sharing this one , very interesting

[@OurBuild]

Cheers mate 👍

[@glennpierce5451]

Did you guys paint/ seal the plywood?

[@mattroussac6399]

Great video. Just wondering if there's any benefit of using 15mm plywood sheets compared to the 12mm you used?

[@mott1992]

15mm will be stronger but stiffer. If 12mm is proven to hold up, then 12mm would be "better" in the sense that it's softer to land on, but it's probably such little difference it's irrelevant.

[@danielortizdecaracas]

Hi bro tell me more about this

[@hvjjhuntervalleyjiujitsu4903]

Did you use structural or non structural ply? Also how’s it holding up

[@7FigExec]

Great job.

[@graces9361]

What glue did you use to glue the noodle?

[@higherjiujitsu]

Nice one!!

[@OurBuild]

Thanks 🤙

[@calairo15]

Do you see any issues with the foam being smashed down as the years go by?

[@OurBuild]

So far so good on this one, if you were really concerned about it you could use a high density foam, but in my opinion the oversized noodle foam works great 👍

[@johnbarabasch5884]

What did he use to screw down the putter perimeter? Look like a 2x4 flipped on its side?

[@OurBuild]

Yep 4x2 with a 3x2 batten screwed together to form the 90 degree edge. The height of the edge timber will be determined by the height of foam you want to install under the ply and the thickness of your mats. Hope that helps.

[@chapsbareng]

Nice!!!

[@Favelapat]

Nice!

[@sabbathvibesmusic]

❤❤❤

[@kevinloerch7540]

Great video, what rollout mats did you use?

[@OurBuild]

Hi Kevin, they are dollimar, link is in the description.

[@marinaosipova7236]

Hello, Where are you located?

[@OurBuild]

Sunshine Coast QLD

[@sydneyshinshi]

Man that was a lot of work. Lucky there were a few of you.

[@OurBuild]

Yeah a bit of work in then mate.

[@PeanutsDadForever]

It never occurred to me that this is a way to go about a sprung floor. Thanks 🇦🇺👴🏻

[@OurBuild]

No worries Mark, glad you enjoyed the video.

[@wagnerlucidorio1606]

Black belt builder ✍️💖👊

[@OurBuild]

Haha thanks mate 😁

[@chadlaskey9034]

How is this holding up? I have herd these don’t last ?

[@OurBuild]

One and a half years mate and still going strong. A lot of people think the pool noodles break down which they do, but only when they are exposed to UV / sunlight. Under the ply and mats they work perfectly 👌

[@chadlaskey9034]

Thank you for the reply. We are About to build our own.

[@nobadmojo70]

@@OurBuild how did you get this idea? What would you do differently? It seems to be a great idea! Thank you for showing how it's done.

[@OurBuild]

@@nobadmojo70 Cheers mate, got the idea from watching other KZbin videos 😁

[@nobadmojo70]

@@OurBuild would you do anything differently? Thanks for the reply.

[@michaelswaine6303]

Awesome work mr Bourke.

[@OurBuild]

That's Don to you Elon.

[@NimblyJimbly]

This is awesome, thanks for sharing! I have a few questions if you don't mind. What are the raw dimensions of the noodles you used? How did you source the supplier? Did they already offer the size you used, or did you have to custom order?

[@timblaikie7698]

The foam will collapse in time.

[@lightyourworld22]

The foam will compact, but it won’t break down. These floors last for years.