Post by Deleted on Aug 6, 2006 15:35:41 GMT -6
Lumber (for long rack)
2 (8') 1 x 4s*
1 (10') 1 x 4*
6 (8') 2 x 4s* (for short rack)
1 (8') 1 x 4*
1 (10') 1 x 4*
5 (8') 2 x 4s*
Hardware
8 (1/2-13 x 4) galvanized carriage screws
4 (1/2-13 x 6) galvanized carriage screws
12 (1/2") galvanized fender washers
12 (1/2") galvanized lock washers
12 (1/2-13) galvanized hex nuts
1-lb. box 3" deck screws
1-lb. box 1-5/8" deck screws
Exterior wood glue
Cut List
side rail* (8') 2 x 4 93" 2
end piece (8') 2 x 4 21" 2
pad (8') 2 x 4 6" 6
upright (8') 2 x 4 36" 4
spacer (8') 2 x 4 6" 4
brace (8') 2 x 4 24" 4
top (8') 2 x 4 24" 2
crosspieces* (8- & 10') 1 x 4 24" 13
*For short version, cut all as above, except for the following:
side rail (8') 2 x 4 46-1/2" 2 crosspieces (8- & 10') 1 x 4 24" 9
Step 2: Assemble the base frame.
a. Attach the end pieces to the side rails with glue and 3" screws. Screw the end pieces into the end grain of the side rails. Check for square by measuring diagonally from corner to corner, adjusting until measurements are equal.
b. Using glue and 3" screws, fasten four corner pads to the base frame so that each is flush with side rail and end piece. Repeat for the two pads centered on each side rail, flush with the outside edge. Check for square (by measuring diagonally) after installing each corner pad. When all pads are attached, turn the base over.
Step 3: Install five bottom crosspieces (three for the short rack).
a. Secure one of the crosspieces so it is centered on each side rail lengthwise and crosswise. Use glue and 1-5/8" screws.
b. Attach four more crosspieces (two more for the short rack) on either side of the center crosspieces at 7" intervals (5" for the short rack), as shown in Figure 1.
Step 4: Assemble the uprights, braces, spacers, and top pieces.
a. Mark 15 1/2" from the ends along the side rails. Put a scrap piece of 2 x 4 under this mark to prop the upright in place. Position the 15-degree angled end of the upright 2 x 4 on this mark, as shown. Clamp the upright to the side rail or drive a 3" screw near the bottom edge to hold in place.
b. Place the angled end of the brace on the inside of the side rail with the long point touching the end piece so that it rests on the corner pad, as shown. Clamp or drive a 3" screw to hold the brace in place.
c. Slide a spacer between the upright and the brace until the top inside corner of the spacer meets the top of the brace. Mark the brace where it protrudes from the inside edge of the spacer. Mark the location of the bottom edge of the spacer on the upright. Remove the brace. Cut off any wood beyond the scribe line, then reattach.
d. Place the spacer between the upright and brace on the mark made in Step 4c. Clamp, or drive a 3" screw in from each side of this junction when aligned.
e. Drill a 1/2" hole through the lower upright junctions, centered as shown. Drive a 4" carriage screw through the hole with the screw head facing the outside. Secure with a fender washer, lock washer, and hex nut. Tighten with a socket or adjustable wrench. Repeat this process through the lower brace junction (use a 4" screw) and at the spacer junction (use a 6" screw) for each corner.
f. Using glue and 3" screws, affix the top pieces to the ends of the uprights.
Step 5: Attach remaining crosspieces.
a. Place the two remaining bottom crosspieces against the uprights. Secure them with glue and 1 5/8" screws.
b. Mark 3" from each of these crosspieces along the uprights. Using glue and 1 5/8" screws, attach the crosspieces at the marked locations.
c. Place a crosspiece flush with the top piece on each end, as shown. Fasten with glue and 1 5/8" screws.
d. Center the last two crosspieces between the two previously installed. Secure with glue and 1 5/8" screws.
