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How I Made It
PAGE 2
COWBOY HAT RACK - MAKING THE TINES
Now I need to make the Tines that will actually hold the cowboy hats and attach to the rack back. This is a fairly simple operation to make these, but it MUST be said that the width of these is very critical especially depending on what type of wood you use. As mentioned in the plans for making these on Page 3 the tines MUST be at least 1 in wide, any smaller and they would not hold-up under use. Wider is better, but the inside radius for the crown of cowboy hat MUST be maintained, so any increase in width needs to come on the outside edges. Be careful not to get too wide as that will take away from the looks of the rack.
Using the model plans located on Page 3, I first make a tine to use as a model for the all future tines. I made mine of of 3/4 in stock, but hardboard would work just as well.

Now, using the model I trace out the tine pattern onto some 1 x 12 stock.

As with the back of the rack described on the previous page, I next move to the
scroll saw, although other tools may be used for this step (I.E, jig saw, band saw, RotoZip saw) and cut out the pattern.

After cutting the tines out, I use my router and a 1/4 in or 1/2 in
round over bit to round over ALL the edged of the tines.
Cutting the Tenons

Next I cut out the tenon on each tenon using the
table saw and a tenoning jig to make the shoulder cuts and the band saw or scroll saw to square off the tenons as shown in the picture on the left. The results of the shoulder cuts are shown in the picture on the right.
Rounding the Corners of the Tenons

Then I rounded the corners of the tenons so they would better fit into the mortises that I drilled and trimmed in the back of the rack. You can just see the rounding detail in this picture.
I do this using a Dremel Tool with a sanding drum attached to remove most of the material from the corners and then I use a cut sheet of 80 grit sandpaper to fine tune the corners to fit into the mortises.
Attaching the Tenons to the Rack

Next I attach the tines to the back by applying
glue to the tenons and inside the mortises, and then insert the tenons into the mortises. I purposely make the tenons to fit snug into the mortises so I there is no need for clamp pressure while waiting for the glue to dry. The snug fit allows the tines to stand on their own and I let them dry overnight.
Finishing the Cowboy Hat Rack

Finally, I apply a stain, in this case Honey Pine, after the
stain dries I then apply 2 coats of Polyurethane with a light sanding between coats.

You'll notice the line routed into the boot just above the heel and continuing to the toe. That's a little detail I put on mine to give some definition to the heel and sole of the boot. It is also done with my Dremel Tool. I paint this with some black enamel hobby paint to give it definition.

Attach 1 or 2 sawtooth hangers, as needed, on the back and your ready for your Cowboy Hats.