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For maximum stability, I made the valet with a flat base, with aluminum rods to serve as a shoe rack. Once assembled, glue the entire hanger support assembly to the back of the back panel, keeping it flush at the bottom. In keeping with the modern look, I used aluminum rod for dowels to reinforce the joints for the top bar blocks and the attachment of the hanger support. The curved hanger consists of six strips of walnut and a strip of aluminum flat-bar, all laminated around a form.
To begin laminating, layer the strips on the form, applying glue to the mating surfaces of the wood. Starting from the middle, bend the strips around the form with clamps, checking to make sure the edges stay flush.
Once the hanger is solid, you need to drill six holes—four for the reinforcing aluminum dowels, and two for hanger support rods. To mount the hanger on the stand, put some epoxy in the holes in the bottom of the hanger and in the top of the hanger arm. Working with the aluminum rods and flat bar for the hanger is similar to working with wood; you just need stronger tools to shape and cut the material. Woodworking Technology student Dan Merkus' upright set of drawers (above), known as the "tower of drawers," took first place in the annual showcase. Pieces on display included a mandolin and a selection of furniture such as tables, storage units and cabinets - all constructed with unique finishes and details. Judging for the event was facilitated by faculty and support staff who considered engineering, overall presentation, movement and finish when reviewing the projects. Last year’s winner of the woodworking showcase, Jordan Gage, built an acoustic guitar that was recently on display at the 2015 Tech Showcase - an event that judges final year projects in a variety of technology-related programs including mechanical engineering, computer programming and interior design. The Woodworking Centre of Ontario is a 50,000 square foot facility at Conestoga that ranks among the world’s top woodworking training centres. As you rough cut the parts, arrange the grain orientation to make the most of your wood’s natural beauty.

To prepare them, raise the blade to half the thickness of the wood and complete a test cut on scrap. Cut the four base pieces, then use a dado blade to cut the half-lap joints that connect everything. Treat the aluminum centre strip the same way, except scuff it well with 100-grit sandpaper first and use slow-cure epoxy in place of wood glue for that lamination. I chose to do a stepped recess to act as a small drawer, but you can configure this tray to hold whatever you’d like simply by switching router profiles. This process will mark exactly where on the drawer front you need to drill to accept the guide rods. Sand the entire project to 180-grit, and continue sanding any exposed end-grain to 220-grit. Second place went to Robert Danner's upright cabinet (below right), with third going to Val Orlov's fortress-inspired cabinet (below left). Students were provided with 120 shop hours to complete their work and had access to basic materials like cherry, walnut and maple. The piece was completed by Dan Merkus who took inspiration for his work from a photo he noticed online.
The doors presented the greatest challenge for Danner, which he says required extra machining due to their raised panels. Using white ash, Orlov took great care to incorporate curves on each piece of the cabinet (including the legs and doors) to create its unique look. Gage’s guitar took first place at the Tech Showcase and he will be presented with the College Mastercraft award. Students have access to custom woodworking and production training as well as the latest in Computer Numerical Control (CNC) and drafting technology.
Assemble the base using wood glue in the joints and a little epoxy in the holes for the rod.
Put a little epoxy into these holes and slide the rod in, then attach the blocks to the back panel.

Put more epoxy into the holes at the top of the hanger and insert 1″-long pieces of rod to complete the hanger mounting. Apply a heavy coat of oil to the entire piece, wait 10 minutes, then wipe off any excess (and any that has found it’s way onto the aluminum). The piece was constructed with walnut and cherry - which Merkus appreciates for their texture and colour - and the drawers were completed using a reverse diamond match.
Drill these holes in two stages, with two different drill bits to make mounting the hanger possible. Begin by gluing the pants bar into place with epoxy, then insert the stretchers with glue applied to the ends. Wait overnight, then repeat the process, rubbing the piece down with #0000 steel wool between coats. Once the epoxy has set and the glue is dry, sand the rod flush to the base using a random orbit sander spinning 150-grit paper or a belt sander.
After the assembly is finished, slide this stop over the end of the rod and secure it in place with a little more epoxy. After five coats, rub down the surface one more time, then apply a coat of dark paste wax and buff. The pieces should be loose enough to fit with gentle pressure, but tight enough to stay assembled without glue.
The easiest way to do this is to centre the hanger back on the form and drill straight down into the form.

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Published at: Storage Buildings

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