Red Team Activity Journal (1 p.m. - 3 p.m.) - The team modifies its design a bit, lowering shelves to provide room for storage of cooking pots and a wine rack. The team cuts 1" x 4" plywood (figure A) to be used as a decorative arch at the top of the rack.
- The team ingeniously uses a bucket as a pattern for a curved design they trace onto the plywood. A scroll saw is used to make the curved cut (figure B), then the design is sanded.
- The triad of arches is screwed into the top railing of the wooden frame, then the Red Team notches corners of the first wooden shelf. The notches will accommodate the poles of the metal rack.
- Decorative tile trim is cut with a miter saw.
Blue Team Activity Journal (1 p.m. - 3 p.m.) - The Blue Team quickly begins the assembly of the unit. First, the team draws an arch 40-1/2" long onto an oak 1 x 6.
- A jigsaw is used to cut the arch, before the team sands the edges.
- A biscuit jointer is used to attach a 1 x 3 into the corner framing, creating the sides of the shelves.
- After cutting lumber down to 1" x 3" and 34-1/2" long, the team uses a biscuit jointer and glue to attach the wood between the two corner frames on the back surface.
- Next, the team uses a hand saw to cut away the excess white frame and plywood from the bottom base.
- Temporary braces and clamps are used to hold the rack together while the glue dries, and copper pipes are inserted into the pre-drilled holes (figure C)
- The team uses a hand saw to cut away excess white framing system from bottom of base. Use jig saw to cut away excess plywood from bottom base.
- After placing 1 x 3s on top of glass blocks as a frame, the team uses and air gun to staple the entire frame to the base.
- The team had originally hoped to eschew the use of nails and screws in favor of old-fashioned joinery. Now running out of time, the team power drills copper sheets (figure D) onto the back of the rack, and secures the copper with nails.
Want to know more about the products used on Warehouse Warriors ? Click here for a complete list of tools, materials and supplies available to our teams.
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