By Chris HillMore in Kitchen
side rails (2) – 3/4 x 2-1/2 x 40
support rails (3) – 3/4 x 1-1/2 x 34-1/2
end rails (2) – 3/4 x 2-1/2 x 22-1/2
copper pipe (9) – 3/4 x 22-1/4
chain (2) – length as desired
Use the hardwood of your choice for this project. Be sure to file the ends of the copper pipe after cutting. To clean up the pipe and give it a bit of luster, rub the pipe thoroughly with steel wool, making sure to rub in the same direction along the length of the pipe.
Finished dimensions: 2 1/2" high, 40" wide, 24" deep
Use Image 1 as a guide for cutting the side rails to shape.
Use Image 2 as a guide for drilling 7/8-inch holes in the support rails.
Attach one support rail flush with the bottom edge (with the angle cut) and centered on one side rail and attach using glue and #18 x 1-1/4-inch wire brads (Image 3). Repeat to create a second side assembly with the remaining side rail and one support rail.
Position the remaining support rail centered and flush with one edge of the two end rails and attach using glue and #17 x 1-1/2-inch brads (Image 4).
Position the end rails flush with the bottom edge on one side rail and against the ends of the support rail attached to the side rail. Be sure the end rail assembly is positioned so its support rail is at the bottom. Drill 3/8-inch countersunk holes for the 3/8-inch furniture buttons, and attach using glue and 1-5/8-inch screws (Image 1).
Cut the copper pipe per the cut list.
Insert the copper pipe parts through the holes in the support rails attached to the assembly (Image 2). To help ease the pipe through the holes, you can apply liquid soap or paste wax inside the holes.
Position the remaining side rail assembly with its support rail flush against the side rails and the copper pipe inserted in the holes in its support rails. Drill 3/8-inch countersunk holes and attach using glue and 1-5/8-inch screws.
Apply glue to the furniture buttons and insert into the screw holes on the faces of the side rails.
Fill any nail holes, sand, stain and apply polyurethane as desired.
Drill pilot holes for the screw eyes about 3 1/2 inches from the ends of the side rails (four total). Drive screw hooks into the end rails (a screwdriver helps to turn the screw hooks) until the threads are fully inserted.
Use a stud finder to locate ceiling joists in the desired location. If the joists are 16 inches on center, drive the screw hooks into the first and third joists. If the joists are 12 inches on center, drive the screw hooks into the first and fourth joists. Be sure to drive the screw hooks until the threads are fully inserted into the joists (allow for the thickness of the ceiling drywall).
Place the chain, through the center link, onto the screw hooks in the ceiling and the ends of the chain onto the screw hooks on the pot rack assembly.
Attach S-hooks to the copper pipes to hang pots, pans and utensils.