Woodworking Newsletter
Vol. 1, Issue 1
October 2006
Rustic Coat Rack

Instructions continued:
  1. Using the 1/2” Forstner bit, drill holes at the layout marks in the backing board. These should be deep enough to accept the tenons on the hammer handles (in our case, 1/2”). Using an 11/64” drill bit, drill a hole in the center of each 1/2” hole all the way through the backing board. Use the mark from the center spur of the 1/2” Forstner bit to guide your drill bit through the center of the hole.

    hammer-head hook


  2. Holding the hammer in place, turn the board over and drill an 11/64" hole through the backing board and into the shaft of the handle. Still on the back of the board, use a countersink bit to make a countersink on each of the holes that you drilled.

  3. Mark the back of the handle tenon with a line parallel to the head of the hammer. Put a small amount of wood glue into the 1/2” hole on the front of the board. Insert the handle tenon into the hole so that the line on the back of the tenon lies straight up and down. This ensures that the handles will be perfectly parallel to the floor and parallel to each other. Hold the hammer in place as you tighten a #8 screw from the back of the board into the 11/64" hole in the hammer handle. The length of the screw depends on the thickness of your backing board. Screws should seat flush in the countersunk recess on the back of the board and sink deep enough into the hammer handles to hold them securely when coats are hung on them (3/4" or more is recommended). Our backing board was about 3/4" thick, so we used 1-1/2" screws.

  4. To screw the coat rack directly onto the wall, make two marks on the front of the backing board at the location of the screws. These holes should be level with each other and placed so that the screws will enter wall studs (an electronic stud finder is helpful for this task). If it's not possible to screw into wall studs, use sturdy wall anchors. Use a 3/8" Forstner bit to drill a hole approximately 1/4" into the front of the backing board. Use a 1/8" twist drill bit to drill a hole all the way through the backing board. As before, use the mark made by the spur of the Forstner bit to center this hole. Using a level to ensure your coat rack hangs properly, install #6 screws into the 1/8" holes so that they seat flush against the bottom of the 3/8" hole.

  5. The wooden buttons or plugs can be stained or painted to match the backing board. After installing the coat rack on the wall, the buttons or plugs can be pushed or glued into the 3/8" hole to cover the heads of the screws.

Hang up your coats and enjoy!

K.S.
Lee Valley Staff
 
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