Welcome to
How I Made It
The next 3 pages show pictures and text on how I make 2 different styles of Cowboy Hat Racks - Boot Shape and the State of Texas - Certain aspects of each are identical, but size and shape of each are quite different and the Texas Shape requires a little more wood due to its size. The first 2 pages are pictures of some of the steps required to make them, and page 3 is a FREE Plan for the Boot Shape, Texas Shape, and the Tines. I hope you enjoy the next few pages and that they will help you if you wish to make some hat racks of your own. Feel free to print out any or all 3 pages if it will help, but please DO NOT re-post or charge for these plans.
Board Preparation

One of the first steps is to prepare the boards need to cut out the hat rack pattern. The picture at left shows where, using my
bisquit joiner, I have joined 2 - 1 x 10's, biscuited and glued together to create 1 board approx. 18 in by 18 in. This is necessary when making a Texas shaped hat rack, if your making a boot shaped hat rack, you can either use a 1 x 12 or biscuit and glue together 2 smaller boards in order to get 1 board similar in size to a 1 x 12.
Trace Pattern onto Board

Next I traced the shape of the hat rack onto the board (See
Page 3 for plans for making patterns for the Boot, State of Texas, and Tines shapes) Be careful to make sure the pattern is square to the board, as the mortises for the tines are referenced off the squared edge.
Cut Out the Traced Pattern

Next I moved over to my
scroll saw and cut out the shapes. You can use several different tools to accomplish this (I.E. jig saw, band saw, RotoZip saw, etc..). I generally do not cut right on the line,but stay back away from the line about 1/16 in and then, using my large drum sander attached to my small drill press and my Dremel Tool with a small sanding drum attachment to clean-up the edges and saw blade marks.
Drill the Mortises

Next I moved over to my
drill press and, using a 1/2" Forstner Bit, cut out the mortises for the Tine tenons to fit into. I then use a sharp chisel to square up the middle of the mortise between the 2 ends. Be carefull when cutting out the mortises in order to make sure the edges are straight to the edge of the rack, so when you attach the tines they will be level.
Rounding Over the Edges

To kind of finish off the rack design, I sometimes use my router to round over the outside edges of the rack with either a 1/4 in or 1/2 in
round over bit, just to soften the edges. I don't usually round over the edges of the boot shaped rack, and just use my own judgement on any other design. I like to round over the State of Texas shape.