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Building the rack is straightforward, but there are a few things to keep in mind.
- Start by cutting all of the panels. As usual, try to minimize the number of
times you adjust the fence on your table saw. Adjust the fence, cut all of
the panels of the set dimension, and then move on to the next set of panels.
- Assemble the the two-piece sides. The key here is to keep the two panels from
sliding out of alignment during gluing and clamping. One easy way to do this
is to start by dry-fitting the two pieces and clamping them together. Make sure
the inner piece is shifted 3/8" from the front of the outer piece. Then drill two or
three small holes the same diameter as some spare finishing nails through
the inner piece and halfway into the outer piece. Finally, glue the
two pieces, using the finishing nails to align the pieces while you apply
the clamps. You can easily fill the holes before painting.
- Assemble the four-piece vertical dividers. Use guide holes and nails as
in the previous step to line everything up while you glue. The key here is
making the front center piece jut out 3/8" from the two side pieces.
- Dry-fit the whole bottom assembly (outer bottom, sides and dividers, and
inner bottoms) to make sure the outer bottom is the correct length. If it's
slightly too long, you can trim it (and the outer top too), or you can wait
until everything is assembled and use a router and flush-trimming bit to
remove the excess. (If the outer bottom is too short, you need to trim
some width from the inner bottom/top pieces.)
- After you're sure everything fits together properly, glue all of the pieces
that form the bottom assembly together. You can use dowels, wood screws, or
biscuits to keep the sides and vertical dividers from shifting during gluing
(and clamping if you're not using screws). Use guide holes and finishing
nails in the bottom pieces to keep them from shifting forward or back.
- Attach the outer top. If you use wood screws, countersink them.
- Attach the inner tops/cleats.
- Assemble and attach the base. It's inset by 1 1/2" on all sides.
- Attach the back. You might also consider doing this last, to make it easier
to paint the insides of the three cavities.
- Cut and attach the half-round trim.
- Fill any guide holes or screw countersinks and sand.
- Prime and paint.
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