Lay out and cut the curves on the four frame pieces and the recess on the front of the vertical pieces. Next, chamfer all the edges on the arm segments and frame pieces with a router spinning a 45° bevel bit. Cut the aluminum rods to size with a hacksaw and remove any burrs with sandpaper.
Finishing Up
Assemble the rack with brass bolts, washers and acorn nuts to secure the pivot points. Attach the cross braces to the vertical supports with stainless-steel screws. Drill pilot holes and counterbores for all the screws. Disassemble the rack and apply three coats of Circa 1850 Tung ‘n Teak oil.
Finally, reassemble putting two-part epoxy in the recessed rod holes and where the cross braces and vertical supports meet. Check that everything moves freely and then apply a dab of epoxy to the brass nut threads to prevent them from working loose. Drill holes in both the top and bottom cross braces to hang the rack.
| You Will Need | |||
| For the Arm Assembles | Material | Size | Qty. |
| Long segments | teak | 3/4" x 1 1/4" x 12" | 6 |
| Short segments | teak | 3/4" x 1 1/4" x 8" | 2 |
| Bolts | brass | 1/4" x #20 x 2" | 6 |
| Washers | brass | 1/4" | 18 |
| Acorn nuts | brass | 1/4" | 6 |
| Long rods | aluminum | 1/2" OD x 19" | 3 |
| Short rods | aluminum | 1/2" OD x 17 1/2" | 1 |
| Mounting frame rod | aluminum | 1/2" OD x 20" | 1 |
| For the Mounting Frame | |||
| Vertical supports | teak | 3/4" x 3" x 15" | 2 |
| Cross braces | teak | 3/4" x 2" x 25" | 2 |
| Screws | stainless-steel | #8 x 1 1/2" | 2 |
Read more in Woodworking Projects and Small projects
0 Comment