A How-To Guide From Bondall in collaboration with Natasha Dickins, DIY Specialist, professional renovator and furniture maker.
DIY specialist and professional furniture maker Natasha Dickins from Little Red Industries says she designed this shelf rack to be the perfect size for a powder room.
‘It serves three basic functions, with soap and hand towel at about the same height as the basin, toilet paper storage at seat height, and a base shelf for spare towels.’
The front rails are cut at an angle so they lean back when positioned flat on the floor, allowing the frame to sit against a wall. The copper caps serve as structural support while adding a little sparkle.
The timber is sealed to protect from moisture damage. ‘I used a mini roller with microfiber cover to apply two coats of Monocel Clear Timber Varnish in Satin that won’t discolour the plywood and highlights the lovely woodgrain,’ says Natasha.
Tip: When drilled, copper tends to breakout around the hole, which makes the cap difficult to remove. So install the caps on one end of each copper rail then add the second cap once the rack is assembled.
WHAT YOU NEED
- 2400 x 64 x 19mm DAR pine x 2
- 897 x 600 x 12mm plywood project panel
- 19mm x 1.5m copper pipe x 4
- Bondall Monocel Clear
- Timber Varnish in Satin
- Mini roller with microfibre
- Cover, tray
- 19mm copper caps x 14
- 20mm copper pipe
- Saddle clips x 12
- 8g x 12mm pan-head screws
- Brasso Metal Polish
- Cleaning cloths
- Measuring tape
- Compound mitre saw
- Circular saw or handsaw
- Combination square
- Quick-grip clamp
- 19mm holesaw
- Sanding block, 180-grit
- Copper pipe cutter
- Felt tip pen, pencil
- Small hammer
- 4mm drill bit
- Phillips head screwdriver
STEP BY STEP
- Cut the Pine Post
Use a mitre saw to cut each 2400mm length of pine to 1175mm for the back posts. This leaves the lengths of the front posts at 1225mm. Then cut the bases of the two front posts at a 15° angle.
- Mark Up The Back Posts
On the back posts, from the base, measure 150mm, 480mm, 810mm and 1140mm, then use a combination square to mark the hole centres. From the top hole there should be 35mm to the end.
- Mark Up The Front Posts
Clamp a back and front post flat on a table. Use a combination square to mark the corresponding holes, then find the centres. Drill the holes in one set of posts, then transfer the holes to the other set.
- Drill The Copper Rail Holes
Use a 19mm hole saw to make the holes, drilling halfway through one side, then turning the pine to complete the hole from the other side for a clean finish. Sand, then seal the posts using the clear timber varnish with a mini roller.
- Cut The Copper Rails
Use a copper pipe cutter to cut three rails for the front at 665mm long, and four rails for the back and top at 700mm long. Clamp the cutter onto the mark, twist it around, tighten slightly, twist and tighten again, until the pipe is cut.
- Secure The Copper Caps
Attach the caps to one end of each of the copper rails, tapping the cap onto the pipe with a hammer, then clamping it to hold secure while drilling through the cap and into the pipe with a 4mm drill bit. Fasten a screw to hold it in place.
- Shine The Copper
Apply metal polish with a cloth, waiting a few minutes before rubbing with a clean cloth to remove it, adding extra along any printed writing or discolouration. Use a second clean cloth for a final polish and buff.
- Assemble The Frame
Position the front posts inside the back posts and thread through the top copper rail. Add the cap, drill the copper and secure with a screw. Working from top to base, install the shorter copper rails at the front, drilling and securing as you go.
- Cut The Shelves
Use a handsaw or circular saw to cut shelves from the plywood project panel to be 600 x 350mm, 600 x 250mm and 600 x 170mm. When mounted, the shelves should be a tight fit between the posts to help keep the rack secure.
- Sand And Sales the Shelves
Sand the shelves, rounding the edges and corners slightly. Seal the shelves all over, including underneath and around the sides, using the clear timber varnish with a mini roller, leaving to dry, then applying a second coat.
- Attach the Shelves
Position the frame with the back posts on the table. Add the base shelf, attaching it with two saddle clips for each rail, working on the front rails first. Turn the frame upright to secure the middle and top shelves.
- Set Out The Rack
To assemble the rack in position, install the caps on the ends of the copper rails to secure, making sure the front and back posts are flush at the top, then turn the caps so the screws are hidden underneath.
There you have it! Stylish, functional and fit for all your bathroom essentials.
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