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Weekly(ish) Blog #2: Weekly(ish) Blog #3: 180922 Shop Blog

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Blog entry by Rob_s posted 09-23-2018 01:33 PM 221 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 1: 180819 Shop Blog Part 2 of Weekly(ish) Blog series no next part

The wife recently finished painting our cabana bath, and wallpaper’d one of the walls with some nautical charts, so we’re about ready to add some towel/robe hooks. Because (a) this is the cabana bath and (b) with two little girls we seem to constantly be looking for places to hang up towels, we wanted a lot of hooks. We’ve used boat cleats as towel hooks elsewhere, so she ordered up 10 from somewhere. Also the cabinet doors are a shaker style so we wanted to mimic that with the towel rack. This is what I came up with.

I was kind of struggling as to how to hang it, and I thought I could use a fench cleat that wouldn’t extend to the ends so I could keep it flush looking without just screwing it directly to the wall.

I initially was going to use MDF, then because of the french cleat design wanted to use poplar, but then my local Home Depot didn’t have any poplar so I wound up with their fanciest pine (yes, I know, fancy pine is an oxymoron). With a single 2×6x8ft I could get all the rails and stiles out of one piece.

Got the wood home, chopped it down to 73”, and hit my first snag. Evidently my chop saw is out of alignement, but in a very odd way. It’s pretty square in the horizontal, and that’s something I can tweak. And it’s square in the vertical at one side of the cut, but not the other. For example, when I lay the 2×6 flat and cut across it, the vertical cut at one of the 3×4” sides is perfect, and the other side it just out. Not quite sure what to do about that frankly, so I moved over to the table saw to make those cuts. Ripped the 2×6 down to the 2.25” width I needed, and then squared up the ends. this worked great for the little 5” sections but the 6’ sections were kind of a bitch to cut even with my Incra 1000HD miter gauge. In retrospect I suppose I could have kicked the extension out for a bit more support.

Once I had everything cut, I laid it all out and started to second guess my dimensions as I felt like the verticals were maybe too short. Ultimately I figured I had all the wood cut I might as well carry on. Here’s what it looked like mocked up.

I figured I probably didn’t really need an actual French Cleat, as I’ll certainly hit at least one stud with a cleat location, and in any case I intend to screw the cleats through the piece to the mounting board on the wall. Still on the fence about this one, actually. More on that in a bit. So I just hogged out 1/4” out of the back of each of the stiles. I’m pretty sure that typically the rails sit between the stiles but with this being such a long piece that didn’t make much sense. I used pocket holes and glue to attach the rails to the stiles.

Then I used the router to hog out the back of the frame to accept the panels. It’s cut 1/2” deep and 3/8” wide. Mostly because this is the bit I had, but the 1/2”+ depth is pretty important to get the 1/4” panel and the 1/4” mounting board to fit behind.

Next I got out my chisel, and tried squaring the corners. I did this on two and figured this was going to take me forever, so instead I went over to the chop saw and put two 22.5-degree cuts on each corner, which fits the rounds without showing through the front.

Here you can see the hogged out back, the pocket holes, the two corners I chiseled, and the 22.5-degree cuts I wound up going with instead.

And here’s where I ended day 1, after sanding the panel faces and edges, and sanding the face of the frame to try and get the stiles flush with the rails. I did remember to sand all of the 3/4” faces of the rails and stiles before I assembled everything, so I’m pretty happy about that. I’ll still have some finish sanding to do on the final assembled part, but the bulk of it is done.

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