OUR PROJECTS: Thread Rack for Jerry K

ORIGINAL PLANS 6-24-2015

EXPLODED ILLUSTRATIONS/BILL OF MATERIALS

SIMPLIFIED DETAILED SKETCHES

MOCKUP OF SPOOL HOLDERS AT 15 DEGREE ANGLE

SPACING FOR THE SPOOLS - 3 1/2" CENTER TO CENTER

PARTS MILLED - PARTS CUT - PARTS DRY FIT

MOCKUP WITH THREE HOLES AND THREE EMPTY SPOOLS IN POSITION ON RACK

SETUP FOR DRILLING 5/8 " HOLES FOR PEGS AT 15 DEGREE ANGLE

SETUP FOR CUTTING PEGS TO 4" LONG

WILL NEED ABOUT 140 PEGS @ 5/8 " DIAMETER

PARTS CUT TO WIDTH AND LENGTH, PARTS MILLED TO THICKNESS

PEGS WITH 3/16" ROUNDOVER MILLED ON ONE END

READY FOR MILLING, DRILLING, THEN ASSEMBLY

FRAME PARTS WERE ROUTERED USING A PORTABLE TRIM ROUTER AFTER ASSEMBLY, USING A 3/16" ROUNDOVER BIT TO EASE EDGES.

SOME MINOR SANDING WAS REQUIRED AFTER ROUTERING

TEN HORIZONTAL SLATS WERE DRILLED WITH 5/8" FORSTNER BIT

13 SPACES AT 3 1/2" = 45.5 INCHES

THEN HOLES WERE DRILLED FOR SCREWS TO ATTACH THE SLATS TO THE FRAME.

LETTERS (2.75 INCHES HIGH) SPELLING 'THREADS' WILL BE GLUED HORIZONTALLY TO TOP (OR BOTTOM) OF FRAME. LETTERS CUT FROM 1/4" THICK WALNUT PURCHASED AT AUCTION IN EDGEMONT, SD.

"THREADS"

FRAME/RACK WAS ASSEMBLED IN SHOP - it will fit in the little red wagon.

The frame was assembled using pocket holes cut with a Kreg Jig - three holes were drilled in the end of each vertical support. It turns out that three was one too many. The first horizontal piece was cut from a thick piece of very beautiful blue pine. I had to recut both the top and bottom vertical parts - not once but twice. Each time the verticals were attached to the horizontals using 3 screws, the horizontals split out along the rings of the wood. Finally, using poplar for the horizontal pieces and only two screws, the assembly went together. But to ensure that the frame was strong and would hold 140 large thread spools without failure, I added gussets made from 1/4" plywood, glued and screwed to the back of the frame at each joint.

GUSSETS WERE ADDED AS A PRECAUTION TO ENSURE THAT THE FRAME WOULD BE ABLE TO WITHSTAND TRANSPORTATION STRESSES. (Note for next time: USING A Half-LAP JOINT AT EACH CORNER MIGHT HAVE ELIMINATED THE NEED FOR THE GUSSETS.)