Materials: Four 48" x 96" pieces of 1/2" drywall
Twenty-four 2" x 4" x 96" studs
Six 1" x 3" baseboard molding
Nine 48" x 96" CDX sheets for 1/2" plywood
4 R-13 insulation w/vapor barrier
2 R-19 insulation w/vapor barrier
One 50' roll of 6-millimeter poly-plastic sheeting
1 dry bag of Quickset tile mortar
1 dry bag of sanded grout
One 250-count 8d common nails
One 500-count 1-1/4" drywall screws
One 250-count 2" drywall screws
One 250-count 3" drywall screws
18 gauge galvanized brads (if you go with shiplap wall covering)
1 dry bag of drywall mud
1 roll of drywall seam tape
2 gallons of primer
2 gallons of paint Special Order Items: 2 boxes of 6" x 6" ceramic tile (ordered to size)
8 wine racks (custom ordered to size)
1 exterior-grade door, insulated, double-pane (ordered to size)
1 cooling unit (WhisperKool Model 1600 was used for this particular project)
1 lighting fixture Gray Mosby, a wine seller and collector, was tired of storing his wine in an old closet in his basement (figure A), so with the help of some friends (including master carpenter, Joe Glass), he built his own wine cellar. Day Four In the last segment, Mosby completed the interior and exterior walls, and now it's time for assembling and installing the wine racks. After much research, Mosby chose a custom redwood racking system, and the first step is to assemble the racks. - The custom racks arrived in hundreds of pieces (figure B), and putting them all together is a big challenge. Mosby and Glass tackled the larger racks for oversized bottles -- such as champagne -- first.
The major components of these racks consist of the following: - Posts and Rails (figure C) -- These actually hold the bottles in place and look like mini-ladders. They are factory built.
- Spacer Bars (figure D) -- The pre-notched horizontal spacer bars hold the post and rail ladders in place in the front and back.
- End Rails (figure E) -- They support each individual section of racking.
- First, Mosby and Glass stood the double-sided or double-railed ladders upright and attached the spacer bars one every five rows (figure F). They started with what will be the backside of the rack. The spacer bars must be flush at the top and bottom with the rails. Simply shoot two nails in the back to hold everything together nice and firm. The top and bottom spacer bars are attached first with 18-gauge 1-9/16" nails in the air gun.
- Double-nail the spacer bar at each post (figure G) to create a firm joint that shouldn't wobble.
- Insert the end rails with single-sided rails in place on each end. It's important to make sure the end rails face inward to hold the bottles in place once the unit is upright.
Tip: When assembling the racks, it's important to hold the spacer bar and post and rail ladders tightly together (figure H) when nailing. - With the backside of the rack complete (figure I), flip it over and work on the front.The front of the rack needs double spacer bars (figure J) placed at the top and bottom of the unit to provide more nailing surface for the crown molding and baseboard later on.
Trick of the Trade: At this point you'll need to switch to shorter nails in order to shoot the nail at a cross-angle (figure K) into the posts. The shorter nail is easier to hide. - Cross nail the posts and rails on the front of the rack.
- Once the rack is complete, it's time to wrestle it into the cellar, where it be installed, but first the bin racks must be assembled.
Note: Bin racks come with pre-built post and rail ladders, pre-notched spacer bars and horizontal center-support posts. Bin assembly is similar to building the individual bottle racks. - Nail the spacer bars into place at the top and bottom first. Be careful to hold the spacer bar flush with the top of the rail (figure L) and square with the post when nailing.
- Once the spacer bars are nailed down on both sides, the horizontal center posts are inserted in the rail notches, which support the center of each bin. It's important that the center posts be nailed down flush and square with the rest of the unit.
- When the bin racks are completed, they are placed in the cellar.
Next are the curved corner racks. Here the assembly is a little more complicated. The curved spacer bars come in two different sizes (the smaller size is for the front of the rack and the larger are for the rear). All of the posts and rail ladders are single-sided. - The spacer bars come pre-drilled, and you can use these holes as a guide for the holes you'll drill into the posts and rail ladders (figure M).
Note: Redwood should be pre-drilled to avoid splitting due to its softness. - The spacer bars for the curved corner racks also come notched to fit two post and rail ladders coupled together. As before with the individual bottle racks, the spacer bars are attached every five rows. They must be held tight and flush with the rails when nailing.
- As with the other racks, extra spacers bars are attached at the top (figure N) and bottom of the rack for securing crown and base molding later. Once the spacer bars are attached, the unit is turned over and the larger, rear-spacer bars are screwed into place.
- The smaller center racks for above and below the tasting table are pieced together the same way. Within a few hours all the racking is complete and ready to be anchored to the cellar walls.
- Each rack must be anchored 1-1/2" away from the back wall to make sure the wine bottles fit properly in the racks, and adjustments had to be made for the cooling unit, which meant that Mosby and Glass had to cut out several rows of racking.
- To secure the racks to the wall, you have to attach angle brackets (figure O) to the racks. The 90-degree angle brackets are attached with screws to the rear corners of each rack.
- Once all the angle brackets are in place, it's time to position the tabletop rack in the center of the back wall. Positioning of this rack is critical since all other racks are connected to this one.
- Next, the rest of the racks are maneuvered into place carefully. The racks must be attached to each other before being anchored to the wall with the angle brackets.
- Using 1-1/4" screws, the glass hanging rack is attached to the two curved corner racks (figure P), then the rack above is nailed into place.
- After the top rack is nailed into place, the bottom center rack is leveled, shimmed and screwed to the two curved corner racks. Then once everything is centered and straight, the center rack is anchored to the wall (figure Q). The table top is screwed into place from below. The center unit is complete.
- Now, working from the center out, the rest of the racks are attached to each other, shimmed, leveled and anchored to the walls.
- The final touch on the racking is to add crown molding at the top and base molding at the bottom. Getting perfect cuts (figure R) for the curved corner units is a challenge, but luckily the crown and base molding came pre-cut from the factory.
Trick of the Trade: When attaching crown and base molding, a great tip is to use masking tape to hold the pieces together (figure S) before attaching with nails. You can use a little bit of wood glue in-between the pieces for added security. Now that Day Four of construction (the wine racking) is done, the final episode (BWC-105) will cover the completion of Mosby's beautiful new wine cellar.
RESOURCES :
Wine Cellar Manufacturer (Wine Cellar Innovations)
Wine Cellar Innovations
Website: www.winecellarinnovations.com
Specialty Food and Wine Retailer (Sutton Place Gourmet)
Sutton Place Gourmet
McLean, VA 22101
Phone: 703-448-1371
GUESTS :
Gray Mosby
Wine Buyer & Collector
Sutton Place Gourmet
6655 Old Dominion Dr.
McLean, VA 22101
Phone: 703-448-1371
James Deckebach
4575 Eastern Ave.
Cincinnati, OH 45226
Tollfree Phone: 800-229-9813
Website: www.winecellarinnovations.com
CEO
Wine Cellar Innovations
Joe Glass
Master Carpenter
Wine Cellar Innovations
See company contact info, above
Christy Lukemire
Design Consultant
Wine Cellar Innovations
See contact info, above
Michael Franz
Wine Critic
The Washington Post
Information private
Tony Wilke
VP Operations
Wine Cellar Innovations
See company information, above
| ALSO IN THIS EPISODE: | | Build Your Wine Cellar: Building and Installing the Wine Racks |
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