–1–Historically, peg racks like this one were hidden. They w - PDF document

–1–Historically, peg racks like this one were hidden. They were fastened to the back walls of wardrobes in the days before wire coat hangers w looking beautiful.WOODWORKS:BEGINNERPROJECTWHITLEDPEGRACK CONTINUED-WOODWORKS:BEGINNERPROJECTWHITTLEDPEGRACK–2–TOOLSREQUIREDSHOPPINGLISTWOODFINISHINGPRODUCTSCUTINGLISTHandTools–Whittlingknife–BlockplanePowerTools–Drillordrillpresswith 1/2"drillbit–Tablesaw–Scrollsa,stationarybeltanddrumsanders(formachine-madepegs)Miscellaneous–Pencil–Safetyglasses–Carpentersglue–Sandpaper–Clean,lint-freecloths–Smallsquare–Woodcarversglove–Leatherthumbguard–Fine(000)steelwool (forPolyshades®)–Respirator–Glovesforfinishing–Mineralspirits–Wate-filledmetalcontainerwithtight-fittinglid–Minwax®WoodFinish™StainBrush RecommendedFinish Prep:Minwax®Pre-StainWoodConditionerStain/Minwax®PolyShades®Honey FinishPine(oranycoloryouprefer) SatinorGlossAlternateFinish Prep:Minwax®Pre-StainWoodConditionerStain:Minwax®GelStainAntiqueMaple(oryourchoiceof GelStaincolors)Finish: Minwax®Wipe-OnPoly SatinorGlossTwo-oneFinishPrep:Minwax®Wate BasedPre-StainWoodConditioner Stain: RackMinwax®Wate BasedWoodStainDeepOcean ® Wate-BasedWoodStain of your choice, available in 50 custom-mixed colors and a Peg–Minwax®Wate BasedWoodStainHarvest Grain ® Wate-BasedWoodStain of your choice, available in Finish:Minwax®Polycrylic®ProtectiveFinishSatin1x4 pine or other softwood (whittled pegs) or oak or otherhardwood (machine-cut pegs). For a 4-peg rack, the back-board will be 20" long. For a longer rack, keep in mind thatthe pegs should be spaced at least 5" apart. Four pegs can be made from a 4" length of 1x6. KePcsParSizeA12-3/4-widebackboard3/4"thickcuttodesiredlength (pegsarespaced5"apart)B4Pegblank9/16"x1"x3-1/2" BEFOREYOUBEGINGood craftsmanship begins and ends with good work habits, so makethe following steps part of your routine workshop practice. If you haveany doubts or questions about how to proceed with a project, alwaysdiscuss them with your shop instructor.Carefullyandfullyreviewplansandinstructionsbeforeputtingatooltotheprojectlumbe. Worksensiblyandsafel.Wearsafetygoggleswhendoingwork thatcreatesflyingchipsandsawdust;weartheappropriate respiratorwhenevermakingsawdustorworkingwiththinners orothersolvents.Attheendofeveryworksession,cleanupyourshopareaandputawayallportabletools.CUTINGANDASSEMBY PROCEDURE1.Using the measurements shown in Fig. B, make a template of thepeg’s profile on a piece of cardboard. Cut the peg blanks to the dimen-sions shown and transfer the profile onto both sides of a blank. Orientthe grain so it runs roughly parallel to the bottom edge of the blank.2.The only tool you need for whittling is a knife. Choose one that’scomfortable; a big handle can give you more control. Make sure theblade is sharp so that you’ll be able to make controlled cuts that areclean and smooth. Always wear a woodcarver’s glove and a leatherthumb guard to protect yourself.WoodworkersTip:Practiceonanextrablank.Whittlingislikepeelingapotato.Youholdthepieceofwoodinyourfreehand,positionthethumbofyourwhittlinghandagainsttheendofit,anddrawtheknifebladethroughthewoodtowadyourthumb.Makedeliberate,shallowcuts,applyingjustenoughpressuretolettheknifedoitsjob.Don’tmaketoodeepacutanddon’tforcetheknife.Thatknifeissharp!You’ll be able to tell which way the grain runs by how theknife cuts. Cutting with the grain is smooth and easy, and so iscutting across the grain, as long as you cut from the outer edgestoward the center. However, cutting against the grain is likely toresult in slips, tear-out and a rough result. When this happens, justturn the piece around so you can cut with the grain. Whittling isso easy that with just a little practice it will become second nature.3.Extend the shoulder lines of the peg’s head and tail across the top ofthe blank, then cut squarely along the lines to establish the shoulders.Remove the waste above the tenon with a backsaw. If you’re not whit-tling the pegs, set up the scrollsaw and proceed with the cutting. Youcan form the rounded shapes with a stationary belt sander and a drumsander.4.If you are whittling, round the back end of the tenon blank withshort, paring cuts until it just starts to fit a 1/2" test hole drilled in ascrap piece. Apply a little pressure and spin it to slightly crush thefibers of the unfinished part of the tenon. Remove the peg and pare therest of the tenon to this mark. Test and pare as necessary for a snug fit.5.Create the convex curve of the head by making shallow, flat cutsacross the end grain. Work down from the top and up from the bottomtoward the middle.6.Cradle the blank in one hand and use a potato-peeling motion. Drawthe knife through the wood to the stop cut at the shoulder. This iswhere a sharp, stiff blade is at its best. Work down by alternately cham-fering (deeply beveling) the outer edges, then removing the centerridge until you reach the pattern lines. Finish the peg by chamfering allouter edges.7.Cut the 2-3/4"-wide backboard to the desired length; you can make it as long as you want, keeping in mind that the holes for the pegs should be spaced at least 5" apart (Fig. A). Chamfer the edgeswith a block plane and then drill 1/2" holes centered 1-5/8" from thetop edge. Drill holes between the outer two pegs on each end forattaching to a wall. Check the size of your fastener to determine the sizeof these holes. Sand the backboard smooth.8.To install the pegs, apply glue around the insides of the holes with a slim wooden stick, then twist the pegs into place, making sure that theirflat sides are perpendicular to the long dimension of the backboard.You can check this with a small square.SAININGANDFINISHINGWoodworkersTip:Thoughyoumaybetemptedtocutshortyoursanding,preparationandapplication,don’tdoit.Thesetasksareveryimportantstepsinobtainingahigh-qualityfinish.Remembe,itisthefinish,justasmuchasthefitandsmoothnessofthepartsthatwilldeterminehowpeoplejudgeyourcraftsman-ship.Toensureanexcellentresult,followthestepsbelowandalsotheinstructionsthemanufacturersputontheirproducts.FINISHING TIPSTestthestainsandfinishesyouareplanningtouseonscrapsofwood.Onthebackofthescrap,markthestain/finishcombinationandthetypeofwood.Allowallsamplestodrythoroughlybeforemakingyourfinalfinishselection.Saveyoursamplesforquick referenceonfutureprojects.Allstainsandfinishesmustbeallowedtodrythoroughlybetweencoats.Rememberthatdryingtimescanvaryduetohumidityandotherclimaticconditions.Ifyouhavesomeleftoverstainorfinish,wipethecanrimsothatstain orfinishintherimwontdryoutandpreventthelidfromformingatightseal. Brushesusedforoil-basedfinishesmustbecleanedwithmineralspirits;forwate-basedproducts,suchasMinwax®Wate-BasedWoodStainsorMinwax®Polycrylic®ProtectiveFinish,cleanbrusheswithwarmwaterandsoap.9.Before staining and finishing, finish-sand all surfaces and ease all the edges. Wipe the piece down with a cloth dampened with mineralspirits. If you’re building the rack with a softwood, such as pine, or aporous hardwood, like maple, you’ll need to prepare it for stainingwith a coat of Minwax®Pre-Stain Wood Conditioner when using an oil-based stain or with Minwax®Water-Based Pre-Stain Wood Conditioner –3– CONTINUED-WOODWORKS:BEGINNERPROJECTWHITTLEDPEGRACK if using a water-based stain. Applying the conditioner will help toensure even absorption of stain and prevent blotchiness that can occurwith some soft or porous woods. Simply brush the conditioner over allthe wood and allow it to penetrate for 5 to 15 minutes. Then removeexcess conditioner with a clean, dry cloth. RecommendedFinish:10.After sanding the piece with 220-grit sandpaper using with-the-grain strokes,thoroughlywipeoffwithaclean,lint-freecloth.ApplyMinwax®PolyShades®followingthedirectionsonthecan.Useanat-uralbristlebrushintendedforusewithpolyurethane. Stirthecancontents thoroughly before starting and periodically repeat the stirringduring your work session. Allow the first coat to dry overnight. 11.Once PolyShades®is completely dry, lightly go over all surfaceswith fine (000) steel wool or 220-grit sandpaper using with-the-grainstrokes. Thoroughly wipe off all surfaces with a soft cloth. Apply a second coat of Polyshades®and set the piece aside to dry overnight. 12.If a third coat is desired for more color or increased protection,repeat step 11. Allow the finish to cure for several days beforeinstalling the rack.AlternateFinish:13.Prepare the wood as you did in step 9. 14.Apply the Minwax®Gel Stain using a natural bristle brush or aclean, lint-free cloth. Allow the Gel Stain to set for about 5 to 10 minutes, then wipe off any excess. Allow the stain to dry for 24 hoursbefore applying the protective clear finish.WoodworkersTip:Whenwipingoffstain,makecertainthatyourlastwipewiththeclothgoeswiththegrainofthewood. 15.Apply Minwax®Wipe-On Poly following the directions on the can. Use a clean, soft, lint-free cotton cloth. Allow the first coat to dry overnight.16.The next day, sand all surfaces lightly with 220-grit sandpaperusing with-the-grain strokes. Thoroughly wipe off all surfaces with asoft cloth. Apply a second coat of Wipe-On Poly and set the piece aside to dry overnight.17.The next day, sand all surfaces lightly with 220-grit sandpaper.Thoroughly wipe off the piece with a soft cloth and apply the third and final coat of Wipe-On Poly. Allow the finish to cure for several days before installing the rack.Two-oneFinish:18.Before applying Minwax®Water Based Wood Stain to a hardwoodor softwood, apply Minwax®Water Based Pe-Stain Wood Conditionerfollowing the directions on the can. After 1 to 5 minutes, wipe off allexcess conditioner using a clean, lint-free cloth. Wait 15 to 30 minutes,then use 220-grit sandpaper to sand off any “whiskers” raised by the conditioner. Proceed to the staining within 2 hours.19.Apply Minwax®Water-Based Wood Stain using either a nylon/polyesterbrushorasoftcloth.Allowstaintopenetratenolongerthan 3 minutes. While stain is still wet, wipe off excess with a cleancloththatsbeenlightlydampenedwithstainusingwith-the-grainstrokes. If a second coat is desired, allow the piece to dry for 2 hoursbefore applying stain. Let the piece dry thoroughly before applying theprotectiveclearfinish.WoodworkersTip: Minwax ® Wate BasedWoodStainavailable in 50 custom-mixed colors and a White Wash Pickling Stain. meansthatyouarenotlimitedtojust traditional wood tones(pine, oak, walnut, etc.). Instead,youcan pickandapplyacolortocomplementthedécoroftheroomin whichthepegrackwillhang.Forthisreason,makesureyoulook over all of the Minwax® stain color charts before making your finalselection.20.After allowing the piece to dry thoroughly, apply Minwax®Polycrylic®Protective Finish following the directions on the can. Stirthe contents of the can thoroughly before starting and periodicallyrepeat the stirring during your work session.21.Using a nylon/polyester brush, work a small area at a time to maintain a wet edge when applying the first coat. Work quickly and make the final strokes in each newly finished section using with-the-grain brushstrokes.22.Allow the finish to dry a minimum of 2 hours. Then sand lightlywith 220-grit sandpaper. Thoroughly wipe off all surfaces with a clean,soft cloth.23.Repeat steps 20 and 21 to apply the second coat. Allow the finishto cure for about 1 to 2 days before installing the rack. PRODUCTSAFETYFor your safety and the safety of those you work with, always read thesafety warnings, which manufacturers print on their labels, and followthem to the letter. Typical safety advice and instructions will containinformation such as the following:WARNING!Removal of old paint by sanding, scraping or other meansmay generate dust or fumes that contain lead. Exposure to lead dust or fumes may cause brain damage or other adverse health effects, especially in children or pregnant women. Controlling exposure to leador other hazardous substances requires the use of proper protectiveequipment, such as properly fitted respirator (NIOSH approved) andproper containment and cleanup. For more information, call theNational Lead Information Center at 1-800-424-LEAD (in US) or contact your local health authority. –4– CONTINUED-WOODWORKS:BEGINNERPROJECTWHITTLEDPEGRACK When using oil-based wood finishing products: CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS. Contents are COMBUSTIBLE.Keep away from heat and open flame. VAPORHARMFUL. Use only with adequate ventilation. To avoid overexposure,open windows and doors or use other means to ensure fresh air entry during application and drying. If you experience eye watering,headaches, or dizziness, increase fresh air, or wear respiratory protection (NIOSH approved) or leave the area. Avoid contact with eyes and skin. Wash hands after using. Keep container closed when not in use. Do not transfer contents to other containers for storage. FIRST AID:In case of eye contact, flush thoroughly with large amountsof water for 15 minutes and get medical attention. For skin contact,wash thoroughly with soap and water. In case of respiratory difficulty,provide fresh air and call physician. If swallowed, call Poison ControlCenter, hospital emergency room, or physician immediately. NOTICE:Reports have associated repeated and prolonged occupationalexposure to solvents with permanent brain and nervous system damage.Intentional misuse by deliberately concentrating and inhaling contentsmay be harmful or fatal. WARNING:This product contains a chemical known to the State ofCalifornia to cause cancer and birth defects or other reproductive harm.DONOTTAKEINTERNALY.KEEPOUTOFREACH OFCHILDREN.When using water-based wood finishing products:CAUTIONS:Use Only With Adequate Ventilation. To avoid overexpo-sure, open windows and doors or use other means to ensure fresh airentry during application and drying. If you experience eye watering,headaches, or dizziness, increase fresh air, or wear respiratory protec-tion (NIOSH approved) or leave the area. Avoid contact with eyes andskin. Wash hands after using. Keep container closed when not in use.Do not transfer contents to other containers for storage. FIRST AID: Incase of eye contact, flush thoroughly with large amounts of water. Getmedical attention if irritation persists. If swallowed, get medical atten-tion immediately. WARNING:Contains Alkyl propanols, ethylene glycol, n-methyl pyrroli-done. VAPOR HARMFUL.Use only with adequate ventilation. To avoidoverexposure, open windows and doors or use other means to ensurefresh air entry during application and drying. If you experience eyewatering, headaches, or dizziness, increase fresh air, or wear respira-tory protection (NIOSH approved) or leave the area. Avoid contact witheyes and skin. Wash hands after using. Keep container closed when notin use. Do not transfer contents to other containers for storage. DO NOT TAKE INTERNALLY. FIRST AID:In case of eye contact, flush thoroughly with large amountsof water for 15 minutes and get medical attention. For skin contact,wash thoroughly with soap and water. In case of respiratory difficulty,provide fresh air and call physician. If swallowed, call Poison ControlCenter, hospital emergency room, or physician immediately. DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.Contains solvents which can cause permanent brain and nervous system damage. Intentional misuse by deliberately concentrating andinhaling contents may be harmful or fatal. WARNING:This product contains a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. KEEP OUT OF REACH OF CHILDREN.SAFE DISPOSAL OF RAGS AND WASTE.Please be mindful of the safe way to dispose of rags and other waste.Rags, steel wool and other waste products soaked with oil finishes orsolvents may spontaneously catch fire if improperly discarded. Placerags, steel wool and other waste immediately after use in a water-filledmetal container. Tightly seal and dispose of the waste materials inaccordance with local trash removal regulations. Be sure to keep thewaste out of reach of children.–5– CONTINUED-WOODWORKS:BEGINNERPROJECTWHITTLEDPEGRACK Thisprojectwasadaptedwithpermissionfrom AmericanWoodworkermagazine,HomeServicesPublications,Inc.,anaffiliateofReadersDigestAssociation,Inc.,Suite700,2915CommersDrive,Eagan,MN55121.©Copyright2002.Allrightsreserved.Forsubscriptionscalltoll-free:1-800-666-3111. 20"5"1/2"-DIA. HOLES2-1/2"2-3/4"1/2"-DIA. HOLES AB WAL ASTENERHOLES 1-5/8" 3-1/2"9/16"3/4"1"TENONTAILHEADNECKFIGA.WHITLEDPEGRACKFIGB.PEGTEMPATE –6– CONTINUED-WOODWORKS:BEGINNERPROJECTWHITTLEDPEGRACK