There was never really a serious chance that I would revert to a permanent table large enough to make the room awkward for day to day purposes but having set it up triggered some interesting reactions and presents a choice that needs serious thought before I act.
Once I had the extension propped up in place to make a 5'x6' table, I placed some troops on it and started trying to picturing a bigger game. Would it look better with bigger units or more of them? Its only 50% more area but that was my first instinct, more figures! It didn't take long to remember that I'm still in the mood to try to finish a few smaller projects and master the art of smaller games, even with big figures.
So, what exactly do I want to do with the extra square footage?
For starters my existing Not Quite Seven Years War forces could use the extra width to give room for an infantry line with cavalry wings. Oddly enough my smallest figures, the 1/72nd ACW, can also use the extra width should I deploy full armies.
Other than that the main use would be for scenarios that would benefit from manouver room without resorting to off table reserves and flank marches or for games such as ambushes of a convoy with the short sides being the entry and exit points. I turned my attention back to how I could add the extra bit which is a light, 1/4", composite board with wood veneer. It'll need a frame like the main table and either a hinge or else some sort of support.
However, when I remade the 4'x5' tabletop last winter I included a way to slide inserts into the end to support an extension on the end to make a 4'x6' or 4'x7' table. It looked very wide and narrow when I tried it and it wouldn't add any depth to scenarios, reinforcements would have to stay off table and ranges remain short, but the battlelines, or the trip for a convoy, could be even longer or the flanks be even more in the air. It would also make the transition from small table to large fairly painless and remove the urge to fiddle with ranges, movement rates and unit sizes. As a bonus it would only take 1 saw cut, everything else is done. It would also be a matter of seconds to install or remove the extension. Its j6st not a shape I'm used to.
I'm going to have to do some trials before I decide.