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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.
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