Ask This Old House general contractor Tom Silva and host Kevin O’Connor build a combination bench/shoe rack out of fir decking.
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Time: 4-5 hours
Skill Level: Moderate
Miter saw [https://amzn.to/2KneNCF]
Table saw [https://amzn.to/2KpFzub]
Sanding block [https://amzn.to/3cBzPJN]
Drill driver [https://amzn.to/2RZfZQV]
Pocket hole jig [https://amzn.to/3avZLoL]
1×4” fir porch decking [https://www.homedepot.com/p/Alexandria-Moulding-1-in-x-4-in-x-8-ft-Douglas-Fir-S4SE4E-Mixed-Grain-Board-001X4-DM096C/206876429]
2×2” baluster stock [https://www.homedepot.com/s/2×2%2520baluster%2520stock?NCNI-5]
Wood glue [https://amzn.to/3bydBIC]
Pocket screws [https://amzn.to/34YTAbK]
Spray-on high gloss urethane [https://amzn.to/2RYEg9A]
Spray-on satin urethane [https://amzn.to/2VKiyY0]
Steps for building a shoe rack:
1. Start by cutting all the pieces of the fir decking. To ensure each repetitive cut has the same dimension, Tom recommends using the stop on the miter saw. Cut pieces for the rails and slats that will eventually make up the shelving for the shoe rack.
2. Using a table saw, cut dados into the rails and rabbets on both ends of each slat.
3. Sand all the pieces individually before assembling using a sanding block.
4. Insert the slats into the rails. Add filler pieces the thickness of the dado and the same width as the slates into the dado to fill in the holes between the slats.
5. Once the positioning of the slats in the dados are correct, pull each filler piece out individually and apply wood glue to the joint. Repeat this process for the rail on the other side of the shelf.
6. Pull out the slats and sand the filler pieces in the rail smooth.
7. Apply wood glue to the slats and push them into the rails.
8. Clamp everything together and allow the glue to dry.
9. Assemble the shelves using pocket screws.
10. Put the boards together for the top. Place the shelves and the base on top of the shelves to determine the right location for the top. Secure the base to the top using more pocket screws. The top does not require wood glue or any additional connections.
11. Apply a finish to the shoe rack. In the video, Tom and Kevin applied a high gloss urethane.
12. Allow the coat to dry and then apply a second coat. Repeat this process for the third coat. For the second and third coat, apply the satin finish.
For lumber, Tom and Kevin used fir porch decking, which can be found at home centers.
To assemble the shoe rack, Tom and Kevin used a combination of wood glue, which is made by Gorilla Glue [https://amzn.to/3bydBIC] (www.gorillatough.com) and pocket hole screws using a Kreg K4 jig [https://amzn.to/3avZLoL] (https://www.kregtool.com/).
For the finish, Tom applied a combination of Clear Satin and High Gloss Water-Based Interior Polyurethane Spray Paint [https://amzn.to/2RYEg9A], which is manufactured by Varathane (https://www.rustoleum.com/).
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Homeowners have a virtual truckload of questions for us on smaller projects, and we’re ready to answer. Ask This Old House solves the steady stream of home improvement problems faced by our viewers—and we make house calls! Ask This Old House features some familiar faces from This Old House, including Kevin O’Connor, general contractor Tom Silva, plumbing and heating expert Richard Trethewey, and landscape contractor Jenn Nawada.
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DIY Shoe Rack | Build It | Ask This Old House