I built a coat tree with arts and craft hooks and all was fine until my Granddaughter (Almost two) wanted to hang her own coat. So I designed to small coat hook and mounted it low. I used a 16d Square Cut Masonry nail and with a little work I had a small coat hook. It is about 2" tall and protrudes about 1.25" from where ever it is mounted. It mounts with two #4 screws.
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Step 1: What You Will Need
Of course, you will need some square cut 16d masonry nails. I used Maze brand. They are well made and a uniform size. They have a lovely black coating (I think it is iron oxide) that gives it a nice forged look. I got a pound of them on the internet for about 10 bucks, including shipping. Besides they are American made. My measurements assume this brand and another brand may require some tweaks. 16d means they are 3.5" long.
You will also need:
- An anvil or metal working vise. My anvil is an old piece of train track. You could also use a chunk of soft steal clamped to a bench.
- A torch I am using a propane torch. I would have bought a bottle of MAP gas if I wasn't so cheep. If you have a torch or blacksmith forge, some much the better
- A hammer (Claw hammer would be fine)
- Small file
- A Rule (Not a Ruler, I made the mistake of calling it that in 7th grade shop and the Shop teacher made me stand at attention at the door to wait in case the Queen of England or someone showed up.)
- a couple a pairs of pliers. These are used as heat proof extensions to you hands.
Step 2: Drill Some Bending Holes in Your Anvil
You will need to drill three holes. 17/64", 5/32", and 3/16". Drill them next to one side of the anvil. You can skip this if you have a metal working vise. An old piece of I-beam makes a good metal working base as does a block of steel. You can find something at the salvage yard.
Step 3: Mark Bend Point on Nail
Using the file, mark a nail, 1.25" down from the top of the nail. This is where the first bend to go.
Step 4: Heat Nail
Heat the nail at the bend point. When using propane you will be lucky to get it a very slightly dull red. (Should have bought the MAP gas.) With propane this may take a a couple of minutes. Note that I am holding the nail with pliers. I do not wear gloves and always remember that THE NAIL IS FRICKIN HOT AND YOU DO NOT WANT TO TOUCH IT. When I say hot I mean swear in church hot. Forgetting this is a self reinforcing action. I have no problem with these conditions but you can get a pair of welders gloves if you wish. (No one would think less of you...... wimp)
Step 5: First Bend
Quickly take the nail and place it in the 17/64" hole. Lightly tap it until it is down to the file mark. Then hit it with your hammer until it is bent 60 degrees. You can remove the nail to reheat as many time as you wish.
Step 6: Bend Lower Hook
This requires making a bunch of small bends to form the curved hook The metal will bend easiest where it is hottest Use the smaller holes in the anvil to hold the nail while you pound it in shape. Start further up on nail and slowly pull and bend. Reheat often. The nail should be able to get hotter as it gets smaller toward the end. When done bending let the nail cool down slowly. Do no place it in water or oil. I have a small box of sand I throw it in.
Step 7: Drill Mounts Holes
Use a #30 drill bit to drill two mounting holes. This can be done with a hand drill if you do not have a drill press. Just drill slowly. If you intend to use flat head screws then follow by drilling a counter sink with a larger bit. 1/4" would be fine
Step 8: You Are Done
Just take some 400 grit sand paper to knock down the sharp corners and you are done. For mounting screws I use #4 zinc coated #4 steel flat headed screws. I soak them is vinegar for maybe 20 minutes to dissolve the zinc coating. What is left is gray steel that looks good with the hook. They will look even better as they develop a patina with age. A whole lot cheaper than buying hand forged screws