Cut List & Parts
- 1 Coat Rack , 24" x 1.5" x 5.5"
- 5 Steel rods , 4.25" x 3/8" diameter
Cut 2x6" board
Cut your 2x6" board to length (24"). Reference the plans in the "extras" tab for more details.
Mark pocket hole locations
Mark out locations for pocket holes that coat hooks will sit it. They are 4" from the edges, and from each other.
Drill your pocket holes
Align your pocket hole jig with the top of the board. You may need to take off the tabs from the end so that the jig will sit flat. Use clamps to secure jig in place. Set drill bit to maximum depth and drill holes.
Drill Pocket holes to final depth
Remove the jigs and drill holes to approx. 2 1/8" deep. See plans for clarification. You can use a permanent marker or a piece of tape to mark the drill bit with the correct depth before drilling.
Cut steel rod
Cut your 3/8" diameter steel rod using a grinder. Grind to top of the rod level to the coat rack.
Cut mail slot
Using your router table, or a dado blade on the table saw, cut your slot for the mail slot (5/8" wide by 7/8" deep, and 1/4" from the front face of the rack).
Cut key hole
Using your key hole bit on the router table, cut a key hole slot which will be used to hang the board. See plans for more details. This is the easiest way to hang it flush against the wall, but you can use any mounting hardware.
Stain, paint, & varnish
Sand your piece. Stain and varnish the wood to the finish of your liking. Deburr (sand down) edges of metal rods and clean with acetone. Spray paint steel rods in the colour of your choice.
Glue steel rods in place
Using epoxy, glue the steel rods in place. You may need to use a hammer to tap them in. Use a rag to prevent damage to the rods while hammering.