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How to Build a Heat-Duct Wine Rack (page 1 of 2)

Grab a stack of double walled heat ducts and a MIG welder, and find a place to bring a DIY wine cellar into view.

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  • Time

    Under Half Day

  • Price Range

    $100 - $250

  • Difficulty

    Moderate

Highlights:

Step 1: Size Up the Project

Begin with the "end in mind." Lay nine empty tennis ball cans on their sides and glue them together tightly. When the glue dries, hold them up to the side of a cabinet. Or hold a few galvanized double wall heat ducts up to a side cabinet or nook to test for wine bottle depth (Images 1 and 2). Got the picture?

With a fresh mental image, it's time to find a place to hang this creative and functional art piece and determine its size: six, 9 or 12 bottles.

Step 2: Rent the MIG Welder

Call around to local building rental supply locations. Ask for a portable MIG flux cored welder. Note: There is a difference between the flux cored and the compressed gas MIG welder. A welding helmet will also be needed for safety protection.

Safety Tip: Using a welding tool has inherent hazards. The light produced is extremely bright and potentially harmful. Always wear proper attire. Sparks are very hot and burn through most fabric. Thick leather gloves are mandatory. Proper ventilation is required. The welding smoke and fumes pose health risks. The welding gun is electrically charged. Treat it as though it will deliver an electric shock. Ask the rental supplier for a detailed lesson and a safety briefing.

Step 3: Tack-Weld the Galvanized Ducts Together

Create a half frame jig by screwing two 2x4s into the work table. When the ducts are aligned side by side in the jig, the tops will be resting against the jig and the sides parallel to each other. Hold ducts together with metal clamps.

Working down the line and on one side only, tack-weld the ducts together (Images 1 and 2). Place four or five tack welds between each duct. The top tack weld should be about four inches down from the top end of the duct. Take care not to burn through the outside wall of the galvanized duct while tacking.

Allow the tack welds to cool before handling. With care, transport the newly created wine rack to the mounting location.

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