Built a Flexi-type rack?

John and others -

I did one of these [two actually] and am about to start a much more elaborate [and expensive] rack project.

I used solid 2" and 4" cherry shelves though [the 4" are just two 2" glued together] and simple 5/8” steel rod because this size rod would easily thread into the salamander spikes you can get from just about anywhere - like Audio Adviser. Cherry is also a super hard wood like maple...just try to sand it and you'll see.

As for drilling the holes, I used a forstner bit too because it is nice, clean, and more precise. But I made a full sized drilling jig from 1/4" hardboard and simply drilled small holes, like about 1/8", to mark the four hole centers – the forstner pilot was easily aligned with this hole. This assured that all the rods would line up perfectly even if the cherry boards where slightly different in size.

I also built steel pieces that would be placed just under two shelves [the bottom and the top ones] that carried mounts for attaching cables. The cables would then very tightly "X" on the two sides and the back for stiffening triangulation.

John, are you in PA…I am in W. Chester, PA, and might have some extra cherry boards when I complete my new rack…whenever that will be.

Thanks to everyone for their suggestions!

Shersta: Elegant solution, having a machine shop point the rods. Could you still thread things on at that end? Don't suppose it matters too much.

Jdubs: My noodling around the web found only 3' and 6' rods. If you need 4' and go with steel of a reasonable diameter, it might not be prohibitive to get 6 footers cut down. I expect a good shop could re-tap the threads at the cut end, too. How many shelves do you need? You might be able to put 4 on 3' rods, depending on shelf and gear thickness. The design is so open, I doubt cooling would be an issue.

Dbld: I'd just picked up a scrap of sheetmetal to make a template as in Richard's helpful instructions, but I like your full size template idea too. Question: why should it matter if the holes in the template match the size of the pilot on the bit? Mightn't one drill the hole to match exactly a center punch, mark all the holes on the piece with the punch, and then drill it? Seeps like there would be next to no slop that way.

I might well be interested in the cherry, depending on timing, etc. I'm now in St. Louis, but I'm through PA a lot, for work and family. Feel free to email, jdoris@artsci.wustl.edu

John

John, It was a while ago when I made these, but you are right. The holes in the template are 1/8", and I just used an automatic punch to mark the cherry through the template. I was mistaken in my desription.

People
To cut a threaded rod is not that hard.How do you think the contractors do it when they cut hundreds of lenghts of 3/8 rods to hung the ducts on ceilings in the buildings.Measure the rod from the end down to 48 inch mark with black marker,run a nut through and passed the mark,use a hack saw with fine metal blade or small grinder,please use eye protection.Once cut remove the nut from the cut side to retool the threads.Sometimes a small file is needed if your cut is sloppy.
For drilling holes on wood shelves,here is what I did.I used a drill press that has a round work table,I made a double fence out of 1x2x16 wood strip,two pices joint together to form a 90 degree corner.Then I secured on the drill press table in the desired distance from the drill point ,mine was I think 2 inches,I think.Every time you drill the shelves your make sure they contact the 90 fence.You can't go wrong assuming the shelving is cut accurate at the store,Home Depot.
George

Hey Guys

I got a great deal on maple shelves...exact same size at the Mapleshade ones. 4 of them for <$250, shipped!.

I haven't received them yet...hope to by the end of next week. They're from a place called Tony's Wood Shop:

http://www.tonyswoodshop.com/

Tony is a super nice guy and I have no doubt they will turn out great.

Now onto the hardware. Samson hardware goes for just over $600, before shipping.

I'll likely just go for McMaster 3/4" 6' rods for $300 for 4 of them (pre shipping) plus all the various brass bits. Will save a few bucks over the Maplesahade hardware.

Anyway, just an FYI for those looking to build one of these racks.

-Jim