This tutorial will show you how to make a Wine rack for 16 wine or beer bottles out of pallets only.
Portuguese version available at www.foradoescritorio.com.br
Gather what you'll need.
Pallets (about 3 or 4)
Crowbar or a pallet prier
Sandpaper 80, 120, 180, 220 grit
Plenty of screws of different sizes
Step 1: Dismantling the Pallets
Use a pallet prier like the one I built or a crowbar for dismantling the pallets.
I made this tool based on this video http://www.youtube.com/watch?v=IpLZgPt_K_k, but there are a lot of other methods listed on instructables or youtube of how to dismantle a pallet.
I asked my wife to demonstrate how to use the tool to show that any person can do it.
After dismantling it, remove the nails.
Separate the wood trying to match size/type/thickness.
Once you have done that, choose the type of wood you want for each part of the wine rack and start transfering your design measures to the wood.
Step 3: Cutting/Gluing Top and Bottom
Start by cutting the wood for the top and bottom panels.
Sand them with the 80 grit sandpaper and try to remove the roughness from the sides so the glue can stick better to it.
Use wood glue on each side of the wood and use the clamp that you have. I didn't have any so I used this clamping method.
Step 4: Sides
As you saw on the design picture at the previous step, I decided to used a pattern for the sides. It's like an arrow going up on one side and down on the other.
To do that, I cut a lot of pieces with 45º on each end. The size of the pieces may vary from my project so I won't say any sizes on this instructable.
After cutting them, dry assamble everything and check if it fits. If it does, start sanding everything. Start with the 80 grit sandpaper and go through the 120 and 180.
After sanding, glue everything togheter. I tried a lot of different methods for gluing those pieces togheter, but none of them really worked out because the pieces were too different from each other, and even cutting them to the exact same length it would still not sit right to the other, so I decided to use staples to hold everything in place.
After the project is glued they will be removed.
Step 5: Screwing Everything Togheter
After all the panels are done, it is time to start gluing and screwing everything togheter.
The pictures are pretty self explaning.
I used as many screws as I thought that was needed.
Don't worry about it. It won't affect the visual after the wine rack is done.
To make it all a little bit more sturdy, i glue and screwed 2 triangles on each top corner. It was removed after it was all mounted.
Step 6: Supports
Cut the wood that you chose for the supports according to the length of the inside of the box.
For both back and front supports you'll need to trace down the shape of the wine bottle onto the wood and cut it with the jigsaw or bandsaw.
For the front support, if you don't have a bandsaw you can use a hole saw that is the size of the top of the bottle and finish the cut with the jigsaw.
Step 7: Check Everything
Dry fit everything and check if it all goes as expected.
I used a ruler to check the space between the supports, and a square to make all the supports follow the same line.
If it all does fit, it's time to use some more glue and screws.
Step 8: Glue and Screw
Glue and screw everything.
I didn't take much pictures of this step but I used glue on all suport sides, and used 2 screws on each side of each support.
Don't forget to pre-drill first so you don't split the pallet.
Step 9: Sanding
Sand everything with the 220 grit sandpaper and for the round places, use a drum sander or a round sander of any type.
Step 10: Back Panel
If there was something to do differently, it would be this step.
I do not advise you to glue and screw the back panel just now, because when you apply the varnish, it will be very difficult for you to access the interior back part.
But, I did it this way.
So use wood glue and again 2 screws for each side of each wood.
Step 11: Finishing
Use a polyurethane based varnish to finish.
Apply at least 3 coats on everything.
Remember to use the varnish in a well ventilated area.
Step 12: Details
After varnishing the wine rack it was time for a few details.
I used screws through wine corks for the feet of the wine rack, and varnished it all, 3 coats.
I spray painted my last name on the back of the wine rack using a template I made earlier.
I also asked my wife to use a pyrography machine and burn my website to the front of the wine rack for a little bit of advertising.
Step 13: All Done
Now you can enjoy your new rustic wine rack!
If you made this as a gift, you'll probably want to keep it for yourself after it is all done.
Any questions please send a comment below.