WOODWORKS: BEGINNER PROJECT

BASEBALL CAP RACK

For rookie woodworkers with a fondness for baseball, this stylized cap rack is sure to hit a home run. It’s the sort of project that makes learning
woodworking techniques fun, and it’s the perfect addition to any fan’s bedroom, or a great gift. Standing 54" tall, it can accommodate as many as
eight caps, so along with displaying your favorite baseball team, there’s room for caps from your other favorite sports and hobbies. Making this
rack will give beginning woodworkers the opportunity to learn and practice a few important, fundamental techniques, such as measuring and
marking, making straight and curved cuts, doing precision wood boring, and shaping edges with a router. And when it’s all assembled, you’ll
learn more about applying and using stains and finishes to protect the wood and keep it looking beautiful.

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TOOLS REQUIRED SHOPPING LIST

Hand Tools Wood Recommendation: Pine or maple
Combination or try square
Assorted files Item Description Size & Quantity
1" paddle bit A Post 1x4, 4 pcs. at 5'
1/2" drill bit B Base 3/4" x 36" x 36" pine or maple
Phillips-head screwdriver veneer plywood, 1 pc.
Handsaws C Tenon 1-1/2" dia. x 6" dowel, 1 pc.
Hammer and nail set D Baseball dowel 1/2" dia. x 2" dowel, 1 pc.
Block plane
Miscellaneous
Hand screw clamp
– One regulation-size baseball
Bar clamps
– Four 1-5/8" drywall screws
Mallet
– Four 1-1/4" drywall screws
Power Tools – Eight Shaker-style pegs, about 3-1/2" long
Drill press and portable drill
Table saw with dado cutter set
Band saw
CUTTING LIST
Jointer Item Description Size & Quantity
Stationary and portable belt sanders A Post 3" x 3" x 54", 1 pc.
Random-orbit sander B Base 3/4" x 30" dia., 1 pc.
Miscellaneous C Tenon 1-1/2" dia. x 2-1/4", 1 pc.
– Pencil D Baseball dowel 1/2" dia. x 2", 1 pc.
– Tape measure
– Safety glasses
– Carpenter’s glue WOOD FINISHING PRODUCTS
– 120-, 150- and 220-grit sandpaper Recommended Finish
– Clean, lint-free cloths
Prep: Minwax® Water-Based Pre-Stain Wood Conditioner
– Respirator
– Gloves for finishing Stain: Minwax® Water-Based Wood Stain–Your Favorite
– Mineral spirits (for oil-based stains Team’s Colors
and finishes) For example:
– Water-filled metal container with Mandarin Orange and Deep Ocean (New York Mets)
tight-fitting lid (for oil-based stains White Oak and Accents™ Midnight Blue
and finishes) (New York Yankees)
– Minwax® Wood Finish™ Stain Brush
or other good quality, natural-bristle Finish: Minwax® Polycrylic® Protective Finish semi-gloss
brush (for oil-based stains and Alternate Finish
finishes) Prep: Minwax® Pre-Stain Wood Conditioner
– Minwax® Polycrylic® Brush or other Stain: Minwax® Gel Stain Honey Maple
good quality, synthetic-bristle brush
(for water-based stains and finishes) Finish: Minwax® Fast-Drying Polyurethane semi-gloss

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BEFORE YOU BEGIN forcing, which could crack the pole around the hole. Before boring
Good craftsmanship begins and ends with good work habits, so make into the pole, test the fit in a piece of scrap. If the peg is too loose,
the following steps part of your routine workshop practice. If you have use a slightly smaller bit.
any doubts or questions about how to proceed with a project, always
discuss them with your shop instructor. 8. To make the base, locate the center of the 3/4" plywood by drawing
• Carefully and fully review plans and instructions before putting a diagonal lines between the opposite corners (Fig. 4). From the center
tool to the project lumber. point, measure out 15" along one of the diagonals. Drive a small nail
• Work sensibly and safely. Wear safety goggles when doing work into the center point so that it’s securely embedded. Tie one end of a
that creates flying chips and sawdust; wear the appropriate string to the nail and the other end to a pencil, adjusting the length of
respirator whenever making sawdust or working with thinners the string so that when it’s fairly taut, the pencil comes down on the
or other solvents. 15" mark. Hold the pencil steady and draw a 30"-dia. circle.
• At the end of every work session, clean up your shop area and
put away all portable tools. 9. Bore a hole just outside the circle that’s big enough for a saber saw
blade, and use the saber saw to cut out the circle. Sand the edges smooth.
CUTTING AND ASSEMBLY
PROCEDURE 10. Use a 1-1/2"-dia. spade bit to bore the through-hole into the base’s
center where the post will be secured by the tenon (C).
1. Glue and clamp together four lengths of 1x4 (A) stock to make a
3-1/2" x 3-1/2" piece that can then be ripped to 3" x 3" and cut to the
11. Clamp the post in a bench vise, bottom up, and locate the center by
54" length. All mating faces should be covered with a thin layer of glue.
drawing diagonal lines between opposite corners. Make an indent with
Use three or four short bar clamps to hold them together. If the clamp
a center punch or nailset and bore a 1-1/2"-dia. hole about 1-1/2"
jaws aren’t padded, insert scrap wood between them and the work piece
deep. Reclamp the post with the top up and once again find the center.
to prevent it from being marred. Wipe away excess glue before it dries.
Drill a 1-1/2"-dia. hole about 1-1/2" deep.
B u i l d e r ’s Ti p : When clamping the 1x4s together, keep all the
12. Cut the tenon dowel (C) 2-1/4" long, apply a thin layer of glue
edges flush with each other. They will have a tendency to slip due
to it and insert it into the post with a slight twisting action to seat it
to the presence of the glue.
and spread the glue inside the hole. There should be about 3/4" of
dowel protruding from the post. Glue the 1/2"-dia. dowel into the
2. When the glue is dry, remove the clamps. Use a table saw to rip the
top of the post.
post close to the finished size. Use a jointer to plane the sides smooth
and to the exact dimension – 3" x 3".
13. Apply glue to the exposed end of the dowel and attach the post to
the base. Use the mallet to ensure a tight fit.
3. Use a table saw or miter saw to cut the post to the exact length – 54".
14. Working quickly, return the post-base assembly to the bench vise
4. Install a chamfering bit into the router. Mark the points where the
with the base up. Bore four countersunk holes through the base and
chamfers stop, 4" from both ends of the post. Then position the router
into the post. Drive in four 1-5/8" drywall screws until the heads are
at the start point of one corner and trace the arc of the router base
slightly below the surface of the plywood.
where it sits on the post. Do the same for all corners at both ends
of the post. Now plug in the router and do the cuts, stopping each
15. Remove the assembly from the vise. At this point, decide how the
when the router meets the trace lines. To stabilize the base, use a piece
piece will be stained. If the pegs will be a different color from the post
of scrap that’s the same thickness as the post (see Fig. 2). Chamfers
and base, proceed with the prep and staining now (step 17). If one
can also be made with a block plane, files and sandpaper.
stain will be used, glue the Shaker pegs into the post, tapping them
lightly with the mallet.
5. To drill into the middle of the baseball, set up the drill press with a
1" paddle bit. Clamp a scrap board to the drill-press table, and drill
a hole 1/2" deep into the scrap. Remove the paddle bit. Do not disturb
STAINING AND FINISHING
the position of the scrap piece (see Fig. 3). Install a 1/2" drill bit Wo o d w o r k e r ’s Ti p : Though you may be tempted to cut short
in the drill press. Set the ball in the hole bored in the previous step. your sanding, preparation and application time, don’t do it. These
Set the drill press for the hole depth (1") and drill the ball. tasks are very important steps in obtaining a high-quality finish.
Remember, it is the finish, just as much as the fit and smoothness
6. Locate the center of the top of the post by drawing diagonal lines of the parts that will have great bearing on how people judge your
between the corners. Bore a 1/2"-dia. x 1"-deep hole into the center. craftsmanship. To ensure an excellent result, follow the steps
listed in this section and also the instructions the finish manu-
7. Lay out peg locations shown in Fig. 5 on the post and bore holes for facturer puts on its products.
them, about 3/4" deep. Don’t install the pegs at this time.
FINISHING TIPS
B u i l d e r ’s Ti p : The stubs or tenons of most Shaker pegs taper • Test the stains and finishes you are planning to use on scraps of
from about 9/16" at the shoulder to about 1/2" at the tip. Assure wood. On the back of the scrap, mark the stain/finish combination
that the holes you bore will accept the pegs without excessive and the type of wood. Allow all samples to dry thoroughly before
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making your final finish selection. Save your samples for quick Thoroughly dust off and wipe all surfaces with a cloth lightly dampened
reference on future projects. with water.
• All stains and finishes must be allowed to dry thoroughly between
coats. Remember that drying times can vary due to humidity and 22. Repeat steps 19 and 20 to apply the second and final coat. When
other climatic conditions. the final coat is dry, apply a small amount of glue to the baseball dowel
• If you have some leftover stain or finish, wipe the can rim so that (D) at the top of the post and set the baseball over it.
stain or finish in the rim won’t dry out and prevent the lid from
forming a tight seal. Alternate Finish
• Brushes used for water-based products, such as Minwax® 23. Apply the Minwax® Gel Stain you’ve chosen using a clean, lint-free
Water-Based Wood Stains or Minwax® Polycrylic® Protective Finish, cloth or natural-bristle brush. Allow the Gel Stain to set for about
must be cleaned with soap and water; oil-based finishes must be 3 minutes, then wipe off any excess with a clean, lint-free cloth. To
cleaned with mineral spirits. achieve a deeper color, you may apply a second coat after 8 to 10 hours,
repeating the application directions for the first coat. Allow the stain to
16. Finish-sand the corners and any other rough spots with 220-grit sand- dry for 24 hours before applying the finish.
paper. Dust off the piece and wipe it carefully with a clean, lint-free cloth
lightly dampened with water. Wo o d w o r k e r ’s Ti p : When wiping off stain, make certain that
your last wipe with the cloth goes with the grain of the wood. This
Recommended Finish way, any stain you might miss during wipe-off will be visually
17. Before applying Minwax® Water-Based Wood Stain to a hardwood minimized by the wood grain.
or softwood, apply Minwax® Pre-Stain Water-Based Wood Conditioner
following the directions on the can. Applying it will help to ensure even Applying Minwax® Fast-Drying Polyurethane
absorption of stain and prevent blotchiness that can occur with some 24. Apply Minwax® Fast-Drying Polyurethane following the directions
woods. After 1 to 5 minutes, wipe off all excess conditioner using a on the can. Use a good quality, natural-bristle brush. Allow the first coat
clean, soft cloth. Wait 15 to 30 minutes then use 220-grit or finer to dry overnight.
sandpaper to sand off any “whiskers” raised by the conditioner.
Proceed to the staining within 2 hours. 25. The next day, sand all surfaces lightly with 220-grit or finer sandpaper
using with-the-grain strokes. Dust off and wipe all surfaces with a
18. Do the staining in two steps, starting on the interior surfaces and cloth lightly dampened with mineral spirits. Apply a second coat of
then do to the exterior surfaces. Apply the Minwax® Water-Based polyurethane and set the piece aside to cure overnight.
Wood Stain you’ve chosen to the wood using either a nylon/polyester
brush or a cloth. Allow stain to penetrate no longer than 3 minutes. 26. On the third day, sand all surfaces lightly with 220-grit sandpaper.
While stain is still wet, wipe off all excess with a clean cloth that’s been Dust off and wipe the piece with a cloth lightly dampened with mineral
lightly dampened with stain. Allow the piece to dry for 2 hours before spirits. Apply the third and final coat of polyurethane.
applying a second coat, if desired. Allow the piece to dry overnight
before applying the protective clear finish. If you’ve used a different PRODUCT SAFETY
stain color for the pegs, now is the time to glue them into the post. For your safety and the safety of those you work with, always read the
safety warnings, which manufacturers print on their labels, and follow
Wo o d w o r k e r ’s Ti p : Minwax® Water-Based Wood Stain is available them to the letter. Typical safety advice and instructions will contain
in 6 wood tones, a White Wash Pickling Stain, 60 custom-mixed information such as the following:
colors, and 8 bold Accents™ colors. This means that you are not
limited to just traditional wood colors (pine, oak, walnut, etc.). WARNING! Removal of old paint by sanding, scraping or other means
Instead, you can pick and apply a color to complement the décor may generate dust or fumes that contain lead. Exposure to lead dust
of the room in which the bench will be placed. For this reason, or fumes may cause brain damage or other adverse health effects,
make sure you look over all of the Minwax® color charts or go especially in children or pregnant women. Controlling exposure to lead
to minwax.com before making your final selection. or other hazardous substances requires the use of proper protective
equipment, such as properly fitted respirator (NIOSH approved) and
19. After allowing the piece to dry overnight, apply Minwax® proper containment and cleanup. For more information, call the
Polycrylic® Protective Finish following the directions on the can. Stir National Lead Information Center at 1-800-424-LEAD (in U.S.) or
the can contents thoroughly before starting and periodically repeat the contact your local health authority.
stirring during your work session.
When using oil-based wood finishing products:
20. Working a small area at a time to maintain a wet edge, apply CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS. Contents
the first coat. Work quickly and make the final strokes in each newly are COMBUSTIBLE. Keep away from heat and open flame. VAPOR
finished section using with-the-grain brushstrokes. HARMFUL. Use Only With Adequate Ventilation. To avoid overexposure,
open windows and doors or use other means to ensure fresh air
21. Allow the finish to dry a minimum of 2 hours. Then sand lightly entry during application and drying. If you experience eye watering,
with 220-grit or finer sandpaper wrapped around a soft backup block. headaches, or dizziness, increase fresh air, or wear respiratory protection
(NIOSH approved), or leave the area. Avoid contact with eyes and skin.

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Wash hands after using. Keep container closed when not in use. Do not SAFE DISPOSAL OF RAGS AND WASTE.
transfer contents to other containers for storage. DANGER: Rags, steel wool, other waste soaked with this product, and
sanding residue may spontaneously catch fire if improperly discarded.
FIRST AID: In case of eye contact, flush thoroughly with large Immediately place rags, steel wool, other waste soaked with this
amounts of water for 15 minutes and get medical attention. For skin product, and sanding residue in a sealed, water-filled metal container.
contact, wash thoroughly with soap and water. In case of respiratory Dispose of in accordance with local fire regulations.
difficulty, provide fresh air and call physician. If swallowed, call Poison
Control Center, hospital emergency room, or physician immediately.
NOTICE: Reports have associated repeated and prolonged occupa-
tional exposure to solvents with permanent brain and nervous system
damage. Intentional misuse by deliberately concentrating and inhaling
contents may be harmful or fatal.
WARNING: This product contains a chemical known to the State of
California to cause cancer and birth defects or other reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.

When using water-based wood finishing products:

CAUTIONS: Use Only With Adequate Ventilation. To avoid overexposure,
open windows and doors or use other means to ensure fresh air
entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory
protection (NIOSH approved), or leave the area. Avoid contact with
eyes and skin. Wash hands after using. Keep container closed when not
in use. Do not transfer contents to other containers for storage.

FIRST AID: In case of eye contact, flush thoroughly with large

amounts of water. Get medical attention if irritation persists. If
swallowed, get medical attention immediately.

WARNING: Contains Alkyl propanols, ethylene glycol, n-methyl pyrroli-

done. VAPOR HARMFUL. Use only with adequate ventilation. To avoid
overexposure, open windows and doors or use other means to ensure
fresh air entry during application and drying. If you experience eye
watering, headaches, or dizziness, increase fresh air, or wear respira-
tory protection (NIOSH approved), or leave the area. Avoid contact with
eyes and skin. Wash hands after using. Keep container closed when not
in use. Do not transfer contents to other containers for storage.

DO NOT TAKE INTERNALLY.

FIRST AID: In case of eye contact, flush thoroughly with large
amounts of water for 15 minutes and get medical attention. For skin
contact, wash thoroughly with soap and water. In case of respiratory
difficulty, provide fresh air and call physician. If swallowed, call Poison
Control Center, hospital emergency room, or physician immediately.

DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.

Contains solvents which can cause permanent brain and nervous
system damage. Intentional misuse by deliberately concentrating and
inhaling contents may be harmful or fatal.
WARNING: This product contains a chemical known to the State of
California to cause cancer and birth defects or other reproductive harm.
KEEP OUT OF REACH OF CHILDREN.

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FIG 1.

23/4"
1
5 /2"

113/4"
3
11 /4"

C
4"

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FIG 2. FIG 3.

1
/2"

1” dia. x 1/2" deep

FIG 4.

B
15"

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