Start by laying out the four rails on two pieces of stock (A)
as shown in Fig 1. By following the
procedure outlined here, you'll be able to get two rails from each
piece of stock and save time in the process. Center four 4" diameter
circles on the rail stock, leaving a 1/2" space between the circles.
Use a hole saw, scroll saw or saber saw to cut out the circles.
Use your Drum
Sander to smooth the insides of your circular cut-outs. Set
up your table saw or bandsaw rip fence to a width of 2-1/2". Rip
cut one 2-1/2" rail from the rail stock. Then turn the same piece
of rail stock and rip the second rail from it. Repeat the procedure
on the other piece of rail stock to get all four rails.
the two ends (B), following the dimensions
on the Bill of Materials. Use your bandsaw, scroll saw, saber saw
or disc sander (with coarse paper) to form the 3/4" radii on both
ends, as shown in Fig 2.
using a router and a 1/4"
round-over bit , shape all the edges of the rails (A),
except for the ends. Use the same bit to shape all the edges of
the ends (B), except the bottoms of
the feet. Sand all pieces.
Locate the positions for the #8 x 1-1/4" flathead wood screws in
the ends (B) as shown in Fig
2. Use your drill press to bore a 3/8" diameter x 1/4" deep
counterbore at each location. Dry assemble the rack together as
shown and clamp it temporarily together using bar
clamps or pipe clamps. Use your portable electric drill to bore
a 1/8" diameter pilot hole through the sides (B)
at the same location and into the middle of the ends of each rail
the rack using glue and #8 x 1-1/4" flathead wood screws. Cover
the screw heads using 3/8" diameter dowel plugs or buttons.
Finish with a stain (if you prefer) and a clear coat of polyurethane
retail price: $20 to $25
View Assembly Drawings: Figure 1,
Figure 2, Assembly
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