Display and Store up to Six Quilts on this Stylish Rack
Making the Top Caps
The Top Caps (C) need to be cut with extreme care. Start with two pieces of stock 1-1/2" x 6" x 12". If you're unable to make them from solid stock, glue-up some stock from thinner pieces, just as you did for the Bases. Once the glue has set-up for 24 hours or more, there are two ways you can go about marking and cutting these pieces:
The first is to either make a template from the diagram or use a pencil compass or set of dividers to mark two half-circles with 4" and 6" radii... then simply cut them out, using your Bandsaw.
The second is to use your Bandsaw with the Bandsaw Circle Cutter to cut the curves. NOTE: If you decide to use this approach, you'll have to start with blanks that are 6-1/2" to 7" wide instead of 6" wide, so your Circle Cutter has a place for its center to “seat” on your workpiece.
When cutting the Caps, don't forget to stay OUTSIDE your lines by 1/32" to 1/16" to allow for sanding down to the finished dimension. Use your Disc Sander for the convex (outside) edges and your conventional Drum Sander or Contour Sanding Drum for the concave (inside) edges.
Turning the Legs
Since some of the areas of the Legs (B) are to remain square, your stock needs to be cut, planed and sanded smoothly to size before turning. Start by sizing your turning stock to 1-1/2" x 1-1/2" x 30", as per the Bill of Materials. Follow our design for the legs as shown in drawing “B”, or create your own design. Just remember that the areas marked “leave square” must not be turned to allow for the attachment of the stretchers, as shown in the diagram. As with the Top Caps, there are two ways you can go about turning these Legs:
The first is to turn each Leg freehand, following our diagram and using a set of Outside Calipers to periodically check your diameters at various points along the length of each Leg.
The second is to create a hardwood template for your design...or to turn your first leg and use it for your design to duplicate your other three legs using a Lathe Duplicator. Using this second approach will help ensure that all four Legs match perfectly.