Hello, I had some time to work on my massage/milking table from my last post on here. I've cut and drilled all the boards, prepared foam for cushioning (from an exercise mat) and got some faux leather. The leather will be wrapped around the foam and board and tacked to the bottom.

Now there's a problem: In order to lock the boards in place, you need to tighten the bolt so that the T-nut engages the rail. I currently have about 1.5cm of foam on my boards that will just squish when subjected to pressure. The leather will deform with it, leading to wear and tear.

I want to give the screw something to press against. I've thought about adding hardware to the boards and cut the foam to fit around it, for example some of those flange nuts. The bolts are M6, so I'd take M8 flange nuts so it won't bind. Those flange nuts are expensive though, I have 28 holes to reinforce. Do you have another idea?

Once I get the tools, I'll also add eyelets (?) to the leather, though it seems difficult to find ones with an inner diameter greater than 6mm, plus the hole punch and clamp that fits that size.

I'll replace the eye bolts seen in the pictures with longer ones that will fit whatever reinforcing hardware I'll choose, and also add a nut and a washer to it to even out the pressure.

Upholstering the headrest with a round-ish hole will be its own challenge, and I'll probably make a post asking for help about that at some point. Though if you have recommendations on how to do that as well, I'd be glad for it.

Thanks!