LumberJocks Woodworking Forum banner
12K views 8 replies 6 participants last post by  SteveW 
#1 ·
Assembly Rack

What started out as a simple clamp rack project grew into an entire assembly center.

I started out wanting a mobile rack for all of my clamps to make assembly easier and avoid the running back and forth for clamps and/or having the work table covered in clamps so there is no room to work. The next thing I knew the project grew into the idea of having everything needed for assembly on a mobile cart - clamps, glue, biscuit joiners and biscuits, dowels jigs and dowels, pocket jig pocket hole clamps and screws, and more!

Here is the completed rack (fully loaded) before final sanding and finishing.

Wood Retail Leisure Market City


I started out with some left over 8/4 Red Oak from my Counter Height Table Top project. I had several long side cuts with wane and one wide board that wasn't good enough for the table top. I also had a large piece (36" by 56") of 3/4 Red Oak plywood from another project, and some left over 3/4" oak stock.

I really enjoy the challenge of making something useful out of scraps and salvaged stock. I set the width dimension of the rack pieces based on the narrowest width. A couple of pieces still have some wane,

Table Rectangle Wood Road surface Asphalt


but i plan on routing the edges with a 3/4" round-over so i could cheat a little.

I started the project by laying out the profile of the "A frames" in chalk on my workshop floor. This helped me work out the dimensions and the angles. I usually start on paper and work everything out, but I decided to just design on the fly this time.

I had a few requirements in mind to start with - the height at 60" with a top shelf of 12" with 10 degree angles, which determined the base width of the A frames.

Wood Easel Gas Engineering Hardwood


I laid out all of my clamps which is what I used to determine a width of 24". Once I put the A frames together I clamped the basic assembly together to make sure the clamps would fit and to work out where the middle shelf and the lower clamp bracket should go.

Building Event City Wood Metal
 

Attachments

See less See more
8
#2 ·
Assembly Rack

What started out as a simple clamp rack project grew into an entire assembly center.

I started out wanting a mobile rack for all of my clamps to make assembly easier and avoid the running back and forth for clamps and/or having the work table covered in clamps so there is no room to work. The next thing I knew the project grew into the idea of having everything needed for assembly on a mobile cart - clamps, glue, biscuit joiners and biscuits, dowels jigs and dowels, pocket jig pocket hole clamps and screws, and more!

Here is the completed rack (fully loaded) before final sanding and finishing.

Wood Retail Leisure Market City


I started out with some left over 8/4 Red Oak from my Counter Height Table Top project. I had several long side cuts with wane and one wide board that wasn't good enough for the table top. I also had a large piece (36" by 56") of 3/4 Red Oak plywood from another project, and some left over 3/4" oak stock.

I really enjoy the challenge of making something useful out of scraps and salvaged stock. I set the width dimension of the rack pieces based on the narrowest width. A couple of pieces still have some wane,

Table Rectangle Wood Road surface Asphalt


but i plan on routing the edges with a 3/4" round-over so i could cheat a little.

I started the project by laying out the profile of the "A frames" in chalk on my workshop floor. This helped me work out the dimensions and the angles. I usually start on paper and work everything out, but I decided to just design on the fly this time.

I had a few requirements in mind to start with - the height at 60" with a top shelf of 12" with 10 degree angles, which determined the base width of the A frames.

Wood Easel Gas Engineering Hardwood


I laid out all of my clamps which is what I used to determine a width of 24". Once I put the A frames together I clamped the basic assembly together to make sure the clamps would fit and to work out where the middle shelf and the lower clamp bracket should go.

Building Event City Wood Metal
I would say you got this all worked out mighty fine. I see in the photo that it's raised up off the floor do you have wheels on it ? Wheels would be something need to move it around the shop floor. Great idea!
 

Attachments

#3 ·
Assembly Rack

What started out as a simple clamp rack project grew into an entire assembly center.

I started out wanting a mobile rack for all of my clamps to make assembly easier and avoid the running back and forth for clamps and/or having the work table covered in clamps so there is no room to work. The next thing I knew the project grew into the idea of having everything needed for assembly on a mobile cart - clamps, glue, biscuit joiners and biscuits, dowels jigs and dowels, pocket jig pocket hole clamps and screws, and more!

Here is the completed rack (fully loaded) before final sanding and finishing.

Wood Retail Leisure Market City


I started out with some left over 8/4 Red Oak from my Counter Height Table Top project. I had several long side cuts with wane and one wide board that wasn't good enough for the table top. I also had a large piece (36" by 56") of 3/4 Red Oak plywood from another project, and some left over 3/4" oak stock.

I really enjoy the challenge of making something useful out of scraps and salvaged stock. I set the width dimension of the rack pieces based on the narrowest width. A couple of pieces still have some wane,

Table Rectangle Wood Road surface Asphalt


but i plan on routing the edges with a 3/4" round-over so i could cheat a little.

I started the project by laying out the profile of the "A frames" in chalk on my workshop floor. This helped me work out the dimensions and the angles. I usually start on paper and work everything out, but I decided to just design on the fly this time.

I had a few requirements in mind to start with - the height at 60" with a top shelf of 12" with 10 degree angles, which determined the base width of the A frames.

Wood Easel Gas Engineering Hardwood


I laid out all of my clamps which is what I used to determine a width of 24". Once I put the A frames together I clamped the basic assembly together to make sure the clamps would fit and to work out where the middle shelf and the lower clamp bracket should go.

Building Event City Wood Metal
Woodshaver - yes I put 4" casters on the bottom shelf so I could move the cart around my shop as needed. I spin it around a lot more than I thought I would!
 

Attachments

#4 ·
Assembly Rack

What started out as a simple clamp rack project grew into an entire assembly center.

I started out wanting a mobile rack for all of my clamps to make assembly easier and avoid the running back and forth for clamps and/or having the work table covered in clamps so there is no room to work. The next thing I knew the project grew into the idea of having everything needed for assembly on a mobile cart - clamps, glue, biscuit joiners and biscuits, dowels jigs and dowels, pocket jig pocket hole clamps and screws, and more!

Here is the completed rack (fully loaded) before final sanding and finishing.

Wood Retail Leisure Market City


I started out with some left over 8/4 Red Oak from my Counter Height Table Top project. I had several long side cuts with wane and one wide board that wasn't good enough for the table top. I also had a large piece (36" by 56") of 3/4 Red Oak plywood from another project, and some left over 3/4" oak stock.

I really enjoy the challenge of making something useful out of scraps and salvaged stock. I set the width dimension of the rack pieces based on the narrowest width. A couple of pieces still have some wane,

Table Rectangle Wood Road surface Asphalt


but i plan on routing the edges with a 3/4" round-over so i could cheat a little.

I started the project by laying out the profile of the "A frames" in chalk on my workshop floor. This helped me work out the dimensions and the angles. I usually start on paper and work everything out, but I decided to just design on the fly this time.

I had a few requirements in mind to start with - the height at 60" with a top shelf of 12" with 10 degree angles, which determined the base width of the A frames.

Wood Easel Gas Engineering Hardwood


I laid out all of my clamps which is what I used to determine a width of 24". Once I put the A frames together I clamped the basic assembly together to make sure the clamps would fit and to work out where the middle shelf and the lower clamp bracket should go.

Building Event City Wood Metal
great cart paul.i think i might have to borrow your pattern,thanks.
 

Attachments

#5 ·
Assembly Rack

What started out as a simple clamp rack project grew into an entire assembly center.

I started out wanting a mobile rack for all of my clamps to make assembly easier and avoid the running back and forth for clamps and/or having the work table covered in clamps so there is no room to work. The next thing I knew the project grew into the idea of having everything needed for assembly on a mobile cart - clamps, glue, biscuit joiners and biscuits, dowels jigs and dowels, pocket jig pocket hole clamps and screws, and more!

Here is the completed rack (fully loaded) before final sanding and finishing.

Wood Retail Leisure Market City


I started out with some left over 8/4 Red Oak from my Counter Height Table Top project. I had several long side cuts with wane and one wide board that wasn't good enough for the table top. I also had a large piece (36" by 56") of 3/4 Red Oak plywood from another project, and some left over 3/4" oak stock.

I really enjoy the challenge of making something useful out of scraps and salvaged stock. I set the width dimension of the rack pieces based on the narrowest width. A couple of pieces still have some wane,

Table Rectangle Wood Road surface Asphalt


but i plan on routing the edges with a 3/4" round-over so i could cheat a little.

I started the project by laying out the profile of the "A frames" in chalk on my workshop floor. This helped me work out the dimensions and the angles. I usually start on paper and work everything out, but I decided to just design on the fly this time.

I had a few requirements in mind to start with - the height at 60" with a top shelf of 12" with 10 degree angles, which determined the base width of the A frames.

Wood Easel Gas Engineering Hardwood


I laid out all of my clamps which is what I used to determine a width of 24". Once I put the A frames together I clamped the basic assembly together to make sure the clamps would fit and to work out where the middle shelf and the lower clamp bracket should go.

Building Event City Wood Metal
Good idea and good work!
 

Attachments

#6 ·
Assembly Cart - Shelf Assembly

I wanted the shelves to be extremely strong and have a good size lip to keep stuff from falling off while I move the rack around. I typically over-engineer my projects, but with as much weight as this rack has on it I am very glad I built it solid.

I glued and screwed (with pocket holes using my Kreg Jig) the A-Frames, but I decided to keep the shelves without glue so I could break down or change the rack. The long shelf sides are the rails that connect the A-Frames so I put 2 pocket holes in each rail.

Wood Hardwood Composite material Plank Rectangle


The pocket hole placement on the bottom of the shelves probably doesn't matter, but I like to lay out the pocket holes pretty consistently. For strength of the assembly, I used a lot of screw holes.

Wood Gas Rectangle Hardwood Wood stain


I use the sawdust hole to align the pocket to my layout lines.

Blue Rectangle Wood Gas Tints and shades


I assemble the shelf attaching the bottom to the sides and rails.

Table Wood Rectangle Wood stain Automotive exterior


I take the ends off and attach them to the A-Frames.

Wood Wood stain Hardwood Plank Gas


I mark the center on the bottom and the end rails for alignment for reassembly

Wood Natural material Rectangle Hardwood Handle


Here is the attached shelf.

Blue Wood Rectangle Hood Mesh
 

Attachments

#7 ·
Assembly Rack - What Goes Where

Here is the Assembly Rack fully loaded - I still have to sand and finish the rack but I wanted to see it fully loaded first. The rigidity and the mobility are great and I am very happy with its utility.

The back of the rack holds every long clamp I own and all of the short clamps go on the rails.

Wood Gas Engineering Cabinetry Shelf


On the right side I hang my mounted Kreg Jig - I can clamp this mounted jig anywhere I need it or take it onto a job site.

Wood Vehicle Gas Hardwood Shelf


The left side holds my 90 degree corner clamps, corner vises, and bar clamp blocks.

Automotive design Motor vehicle Luggage and bags Bag Shelf


The top shelf holds all of my glues and adhesives, biscuits, and dowels within easy reach.

Shelving Drink Gas Retail Shelf


The mid shelf holds pocket hole screws, nails for my pneumatic nailers, dowel jigs, pencil cup, tape measure, square, and a place to set my drills.

Shelf Shelving Headgear Personal protective equipment Retail


The bottom shelf keeps my pneumatic nailers, biscuit joiners, Kreg Jig kit, and bucket of face frame clamps.

Motor vehicle Automotive tire Wood Luggage and bags Bag


I now have everything I need for assembly on a roll-around cart - well almost - it is only missing the compressor and the kitchen sink!
 

Attachments

#8 ·
Assembly Rack - What Goes Where

Here is the Assembly Rack fully loaded - I still have to sand and finish the rack but I wanted to see it fully loaded first. The rigidity and the mobility are great and I am very happy with its utility.

The back of the rack holds every long clamp I own and all of the short clamps go on the rails.

Wood Gas Engineering Cabinetry Shelf


On the right side I hang my mounted Kreg Jig - I can clamp this mounted jig anywhere I need it or take it onto a job site.

Wood Vehicle Gas Hardwood Shelf


The left side holds my 90 degree corner clamps, corner vises, and bar clamp blocks.

Automotive design Motor vehicle Luggage and bags Bag Shelf


The top shelf holds all of my glues and adhesives, biscuits, and dowels within easy reach.

Shelving Drink Gas Retail Shelf


The mid shelf holds pocket hole screws, nails for my pneumatic nailers, dowel jigs, pencil cup, tape measure, square, and a place to set my drills.

Shelf Shelving Headgear Personal protective equipment Retail


The bottom shelf keeps my pneumatic nailers, biscuit joiners, Kreg Jig kit, and bucket of face frame clamps.

Motor vehicle Automotive tire Wood Luggage and bags Bag


I now have everything I need for assembly on a roll-around cart - well almost - it is only missing the compressor and the kitchen sink!
Great blog series and great project. I definitely have to borrow your design and build this!
 

Attachments

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top