How to Build a Coat Rack for Your Wall
Step 5
Construct the Shelf and Attach It to the Back and Ends
Edge glue the two four-inch-wide top shelf (B) pieces from the cut list, using biscuits or dowels if you wish. When finished, you should have one board measuring 8-in. by 44-inches. However, if you must clean up the edges to achieve a tight glue joint, a slightly narrower top shelf will be just fine.
While the top shelf is clamped and drying, cut a dozen 3/8-in. plugs to cover the screws in the top and later for installation.
Once the top shelf dries, clean up the glue squeeze-out, sand the entire board and lay out the holes for attaching the top to its back and sides. Do this by laying the top upside down on your bench with the end and back assembly on top of it. Then draw the outline of the top with a pencil. Before tracing the outline, make sure that the sides are perpendicular to the back and the entire assembly is centered on the top.
Using the outline, lay out the screw placement locations and drill 9/64-in. holes from the bottom side of the top shelf all the way through the board. It doesn’t matter how many screws you use here. Just make sure you fasten them in both ends (A) and the top rail (C) to hold the coat rack square and keep the top shelf from warping or twisting.
Once you’ve drilled the through holes, sand or erase the outline you traced on the bottom of the top. Turn it over and countersink the 9/64-in. through holes 5/16-in. deep with a 3/8-in. countersink bit.
Attach the top with wood glue and #8 x 1-1/4-in. flathead or trusshead/pocket screws. When you’ve tightened all the screws and secured all the coat rack pieces together, glue in the top plugs. Let them dry and sand or trim them flush.
Step 6
Sand and Finish
With the coat rack assembled, sand and finish the piece and four extra 3/8-in. plugs to your desired liking. If you live in a wet or snowy climate, apply polyurethane as a topcoat. This protects the wood from the wet mittens, scarfs and hats that will inevitably collect on the top shelf.
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