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"The Plyrack" Plywood Surfboard Rack
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This is my design for a rack for storing surfboards and windsurfers. It has several advantages over other systems
I've seen:
- It is freestanding--no holes need to be drilled in your walls, and it fits in any room.
- It stores your boards horizontally--this is important if you have low ceilings and/or long boards.
- It folds flat--for storage and moving.
It took me about 5 hours to make the rack (or rather it would have if I hadn't been designing it as I went along)
and cost me US$38 for materials.
Materials and tools:
One sheet of ¾" plywood (or two half-sheets), wood glue, four 3" hinges, twenty-four ½" wood screws
(for the hinges) and five 1¼" screws.
The tools you'll need are an electric jigsaw with thin blades and a
screwdriver. It's also nice to have a circular saw for some of the straight cuts,
but you can make do with the jigsaw if you don't mind a few wiggly edges. A jigsaw
can be made to cut straight lines if you clamp a straight-edge to the plywood and
use it as a guide for the saw.
Instructions:
Step 1: Look at
figure 1
and draw shape "A" onto your plywood. There are two versions of figure 1, one with a
metric
grid superimposed on the shapes, the other with a
non-metric
grid superimposed (the plywood shapes were designed using centimetres, so it is probably easiest to use the
metric version).
When drawing shape "A", use the blue dots in figure 1 as guides to draw out an angular version
of the shape, then round off the
sharp edges by drawing smooth curves. The rounded edges are aesthetically pleasing, but more importantly,
rounding off the corners on the undersides of
the shape's "arms" should give them a bit more strength. The notch on the base of shape "A" is designed to
interlock with a similar notch in another piece
of plywood; you want a snug fit, so for now, measure the notch to be somewhat less than ¾" wide.
Step 2: Cut out shape "A" from the plywood. It is easy to overshoot corners with the jigsaw, particularly
if your blade is a bit wide, so be careful.
Again, make sure you don't make the notch in the base too wide--you can always widen it later.
Step 3: Use shape "A" as a template to trace shape "B" onto your plywood, then cut shape "B" out.
Step 4: Look at
figure 2
and draw out shapes "C", "D" and "E" on your plywood. As with figure 1, there are two versions of figure 2, one
with a
metric
grid superimposed on the shapes, the other with a
non-metric
grid superimposed.
Step 5: Cut out shapes "C", "D" and "E", using a circular saw, if you have one. Shapes "C" and "D" are
straightforward, but shape "E" requires a bit
more care. As with shapes "A" and "B", the notches in shape "E" should be made somewhat narrower than ¾" at
first. It is important to cut out only
one of the notches in shape "E" for now; the exact placement of the second notch will depend on the size
of the hinges you bought and the accuracy
of your other cuts.
Step 6: Assemble the rack. Attach shape "D" to shape "A" as in figure 3, using
the 1¼" screws and some wood glue
(shape "D" allows the entire rack to fold up flat when it is completed). Next, screw the hinges onto the edges of
shape "C". Finally, use the hinges to
attach shape "C" to shapes "B" and "D". Note that the hinges attach to the surfaces of the verticals, rather than
to their edges. If the hinge barrels
are of large diameter, it may be necessary to gouge out little trenches for them with a chisel or a screwdriver
in order to make the hinges lie reasonably flat.
Step 7: Attach the cross-brace (shape "E"). The notches in the cross-brace interlock with those on shapes
"A" and "B", but at this point, only one
of the notches on the cross-brace should have been cut. First, widen this notch and the one on the corresponding
upright support (shape "A" or "B") as
necessary to get the two pieces to interlock snugly. Then, with shapes "A" and "B" parallel, determine the
correct location for the second notch in the
cross-brace and make the cut. You may want to cut a length off one or the other end of the cross-brace to make it
symmetrical.
User contributions
"Soulbrother Mike" has sent me some photos of the rack he built from
my plans. They are worth looking at, because he did a better job than
I did of building it, and he added a handy shelf to it as well.
Other surfboard-rack sites
Here are some other surfboard storage-rack websites I've come across. Let me know by
e-mail
if you know of any others.
Do-it-yourself racks:
"Bud's Surfing Life"--A "wall" rack (actually mounts between the floor and ceiling) that doesn't damage your walls.
kdough.net--Kevin Dougherty's design; similar to Bud's.
Rod's Wave Riders--Ceiling-mounted PVC rack.
How to build a surfboard rack at home--Plans for making a wooden "garage rack".
Commercial rack sales:
The list of links to commercial rack
sales still exists, but it is no longer being maintained; there
are now too many commercial sites out there to keep track of.
If you have any questions or comments, then please
e-mail me.
Let me know if this design worked for you!
Bonus feature! How to Surf
Site last modified: March 13, 2007