Wall Racks for Displaying Surfboards |
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This week on the blog I showed pictures of wall racks for
surfboard display. One of our valued customers inquired how much they
were. I replied $300.00. He was shocked (and someone unfamiliar with
the process would be). ![]() ![]() So here is how they are made. Making Wall Hanging Board Holders 1) Round trip drive to Santa Ana to get the wood that ends up at about $25 cost per set. I take a template to try to make sure I can get the racks from the 1 7/8" thick wood that comes in 8 to 10 foot lengths and different widths. 2 Hrs. (at least). 2) Back at home lay out the board holders on the wood. It will take 4 to 6 sets to utilize all of the wood. Half an hour, 4-5 minutes each. 3) Skil saw them into workable lengths keeping any strips that are at least 2 feet long; more about that later. 10 minutes per set. 4) For the board holders, I drill a 1 7/8” hole at the location of the hook that holds the board so that the band saw cuts out correctly. This must be precisely done. Twelve holes in 1 1/2 hours, about 7 minutes each. 5) Now the board holders must be cut out on the band saw utilizing the hole that was previously drilled so that this part is already cut out. I cut carefully, very close to the pencil line. About 10 minutes each board holder, 20 minutes for each set of holders 6) Each holder is routed out using a ¾” thick jig that is double sided taped to the wood. This is done using a pin router system on the table router. It is done in 3 stages, as the hard rock maple is so hard that there is kickback even with this method. I have about a 20% loss with kickbacks. 15 minutes each holder times 2 for each set. 7) With jig still attached, each edge is then sanded with coarse then medium paper with a drum sander that has a template guide using the drill press. 10 minutes sanding with each grade of paper, times 2 for each set.
9) Table saw each mounting block to size. 5 minutes each, times 2 for each set. 10) On the table router, cut out each block using jig & 2-sided tape. 10 minutes each, times 2 for each set. 11) Go through the above edge sanding process for each mounting block. About 40 minutes of sanding on each block, times 2 for each set. 12) Lay out marks for mortises on bottoms of the board holders. Set up plunge router and route 2 mortises on the bottom of each board holder. About 15 minutes each times 4 for each set. 13) Lay out marks for mortises on the mounting blocks and route out 2 (precisely matching) mortises. About 5 minutes each, times 2 for each set. 14) Remember the strips I saved? Go to the table saw and cut 1” x 11/32” strips about 2 feet long. About 15 minutes. 15) Set up drum sander on the drill press with a fence that is about .300 away. Then grind this strip that is .3125 (5/16”) to .300. About 20 minutes. 16) Set up table router with ¼” round over bit and round over all 4 sides. About 15 minutes. 17) Measure depth of mortises in the board holders and add to that the depth of the mortise in the mounting blocks. Cut the strips to this length. These lengths are the tenons that make up a very strong joint. About 15 minutes. 18). Switch to 3/8” round over bit on the table router and round over each side of the board holders and mounting blocks. 5 minutes each holder, 5 minutes each block totaling 20 minutes per set 19) Drill 1” hole on the mounting block that holds the lag bolt cap. 5 minutes. 20) In same location, drill hole just bigger than washer and just deeper than the head of the washer plus washer, plus the depth of the cap. About 5 minutes. 21) In same location, drill 5/16” hole the rest of the way through. About 5 minutes. 22) Now the hand sanding that is 80, 100, 180, and down to 220 grit. By hand, it takes about 4 hours PER BOARD HOLDER. I’ve timed it. I have developed some sophisticated power machinery and can do one in about 1½ hours. Remember, there is a pair, so double this. 23) Hand sand each mounting block, also down to 220 grit. About 30 minutes per block times 2 blocks per set. 24) With block plane, level the bottom of the board holder for nice fit against the mounting block. About 20 minutes each, times 2 for each set. 26) Drill through a hole between mortises in mounting blocks. 27) Counter sink that hole on the bottom of each mounting block. About 5 minutes per set. 28) Drill smaller sized hole between mortises on the board holder that matches the same location as the mounting blocks. This is all done with a special marking jig. About 10 minutes per set. 29) Assemble with glue on tenons and bottom of the board holder. Place screw into the bottom of the mounting block and draw it and the board holder together. About 10 minutes each, times 2 for each set. 30) Spray each set using clear gloss paint at $30.00 per gallon. About 5 minutes each set and 1 quart per set. 31) When dry, sand each set with 320 grit. About 20 minutes per set. There are 4 coats of clear gloss per set. About 1 hour and 20 minutes per set sanding and painting. | |||



