Australian Handyman - July 2018

ELBOW

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O^1 Cut copper pipes
Follow the cutting list to measure, mark
and cut the copper pipe lengths for
the rack frame. Use the irst cut length
as a template for multiple cuts for the
top and base lengths, crossbars and
uprights. When marking, use a square
to ensure the ends are lush. Use a pipe
cutter to get clean cuts without burrs.

O^2 Lay out base frame

Lay out the framework for the base

so you can join it all together. Start by

attaching a tee to a 220mm pipe length.

Add a 25mm piece to the tee, then attach

an elbow to make a short end. Attach

a 530mm piece to each tee to make the

two base crossbars. Repeat this at the

other end to complete the base.

O^3 Secure base frame

Use the crimping tool, or an epoxy

adhesive, to join the pipes for the base

frame. Before crimping them, make

sure that the elbows on the ends are

facing downwards on the workbench.

Place the crimping tool over each join

and squeeze together the arms of the tool

to seal the pipes. Turn the base face up.

O^4 Attach the frame pieces
Crimp the four 520mm uprights to the
elbows on the base. Attach an elbow,
facing parallel to the base, to the top of
each upright. Attach a 135mm joining
length to the elbow, a tee to hold the top
crossbar, and another 135mm length to
the other upright elbow. Repeat for the
other end. Attach the top crossbar to the
tees and crimp the joins. Polish the pipe
frame with metal cleaner and a rag.

O^5 Make the formply base

Measure and cut the base to it the

rack. Here it is 575 x 310mm. Use the

straightedge clamp and the circular saw

to cut the base. Use the sander to sand

the painted formply edges with 120 grit

paper. Use the formply ofcuts to make

two 210 x 95 x 19mm blocks. Position

them, with the castors, at both ends of

the base inside the crossbars, so the

castors will have room to swivel.

O^6 Complete the base

Attach the formply base to the frame

with saddle clips and 15mm screws.

Mark where the screw holes will be on

the formply blocks for the four castors.

Predrill four holes for each castor with

a 3mm bit through the ply and into the

base. Use an impact driver to secure

the castors to the blocks and base with

35mm screws. Give the copper a inal

polish with metal cleaner and a rag. ❖

PIPE

CUTTER

COPPER

PIPE

220mm PIPE

LENGTH

TEE

25mm PIPE

LENGTH

CRIMPING

TOOL

520mm

UPRIGHTS

220mm

LENGTH

CROSSBARS

CIRCULAR

SAW

STRAIGHTEDGE

CLAMP

FORMPLY

CORDLESS

DRILL

ELBOW

530mm

CROSSBARS

TEE

TEE

220mm PIPE

LENGTH TEES

ELBOW

3mm PILOT

HOLES

FORMPLY

BASE

FORMPLY

BLOCK

SADDLE

CLIP

15mm

SCREW

CASTOR

35mm

SCREWS

Handyman.net.au JULY 2018 101

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