DIY Network

Making Stainless Steel Slats The magazine rack's stainless steel slats are created. From "Freeform Furniture" episode DFFF-111

Host Amy Devers makes 20 stainless steel slats for the magazine rack, and uses a random orbital sander to give the slats a matte finish.

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Host Amy Devers makes the slats for her modern magazine rack.

Materials:

Pre-finished colored plywood
Cut list
Tape measure
Safety glasses
Stop block
Clamps
Wax pencil
Fence with 2 slots--(1" apart and small piece of stainless steel bar stock inserted in one)
Dado blades
Ruler
Pencil
Template for cutting window
Drill bit as large as jigsaw blade
Double stick tape
Flush trimming bit
45-degree router bit
Blue tape
Lint free cloth
Wipe-on polyurethane
Sharpie
Stainless steel bar stock
Abrasive cut off wheel
Welding jacket
Earplugs
Face shield
Pre-fabricated feet
Countersink bit
Screws

Tools:

Table Saw
Cross-cut sled
Drill
Jigsaw
Router
220-grit hand sander
Disc sander
Random orbital sander
Combination square
Screw gun
Awl

	Figure A
	Figure B
	Figure C
	Figure D

Making Stainless Steel Slats

1. The stainless steel bar stock for the metal slats typically comes in 12' lengths. Cut it in half to make it more manageable. You can have it cut by a metal supply company or you can cut it down yourself.

   Note: An abrasive cutoff wheel was used (figure A). It is designed specifically to cut down metal stock like bars, tubes and rods.

   Safety Tip: Wear a face shield, welding jacket and ear protection when using the abrasive cutoff wheel.

2. Make sure that the marks line up with the saw and tighten the vice to hold the metal in place and cut.

3. Use the slat you just made for the next cut (figure B). Repeat the process until you have 20 slats cut.

4. You now need to get rid of the sharp edges. The sharp edges are called burrs. Debur or smooth out the ends on the disc sander. If you don't have a disc sander, you can use a metal file.

5. Position the slat up against the fence to insure a smooth, even result. The disc sander spins in a counterclockwise direction so it is important to hold the bar on the left side of the disc or it could fly out of your hand (figure C). Press the bar completely flush against the sander until the burrs are gone.

6. Continue sanding and measuring until it is exact. The first piece becomes the template for cutting the others.

7. Debur each piece on both ends and then use the template as a guide by holding the other pieces up against it. Do this until all 20 are exactly the same size.

8. To put the finishing touches on the metal slats, sand them using a random orbital sander (figure D) to give them a matte finish.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com