I built a few of these for Christmas presents this year and wanted to share the build details. I found the basic design details
and have included some more detailed step by step instructions here.
- One (1) Ceiling Fan Rod 9.5″ longOne (1) 32″ of 1″x6″ pine board, 32″ long
- 1/4″ plywood, I bought a sanded board that was 2’x4′ and could have made at least 6 of these with that board.
- Wood stain
- Wall mounted bottle opener (I got mine at Amazon)
Remember measure once cut twice!!! Wait that’s not how it goes!
I like to use a speed square to draw a quick line, its not necessary with a miter saw, but it is very useful to have a straight line if using a circular saw.
I always like like to get my eyes on the same plane of the blade to see how well it will cut “the line.”
Finished initial cuts (I was making 2 of these). In hindsight, I should have made more as it’s easy to make a few at a time.
Get out that 1/4″ sanded plywood and ideally a table saw. This could also be done with a skill saw and a piece of wood (2×4) clamped down as a guide. Be sure to be safe here, especially if you are using a falange remover… I mean table saw!
If if you are using an old table saw like I am, double check that your blade is square with the fence. We need to cut 1″ and 4″ strips. The 1″ strips are for the sides and the 4″ strips are used for the bottle separators.
This is where this project starts taking shape. If you’ve got a miter saw, set it for about 18 degrees (or whatever angle you like) and start your cut about an inch in. Just remember how far in you start the cut because you will need to replicate that for the other side. Flip the board over and make the same cut on the other side. If using a handsaw you’ll need to mark your lines to cut off the corners and clamp to a firm surface before cutting.
Cut plywood strips to length. Cut 1″ plywood strips in 10″ segments. You’ll need 4 of these for this project. Cut the 4″ strips into 3 pieces, two that are 5-1/2″, and one that is 8-1/2″.
Cut groove in separators. This may have been my favorite part. I borrowed a friends router table and that made this step extremely simple. If I did not have the router table I might have tried a few passes with a jigsaw, or even my regular router with some guide boards clamped with these separator pieces.
The photo below shows the guide I clamped in for the router table. I used a 1/4″ router bit and spaced the edge of the wood 2-3/4″ from the center of the bit. I set the back guide so that I would only “router” to 2-1/8″. This ensures a good fit for the separators. These settings work for all three of the 4″ pieces. For the 8-1/2″ piece after you router out one side, just flip the piece over on its short end and get the other side! Magic!
Now all of the pieces have been cut to size! The toughest part is finished.
Sand sand sand. One of the least fun parts, but very important to making a “professional” looking finished project. You want all of the edges smooth and the angle on the side pieces to be a bit rounded so there are no sharp corners.
Drill handle holes. I used a 1-1/16″ bit that I picked up on Amazon to drill holes approximately half way through the side boards. This way the handle/rod does not stick out the end and is contained within the side boards.
Stain. I used a pre-stain that helps the stain to be applied more evenly, followed by a single coat of stain on all of the wood pieces.
Before and After! One coat of this stain looked really good so I did not need to apply a second coat.
Assembly – This is where you put all the pieces together. Since the bottom piece supports all the weight and is only connected to the handle via the sides, you need to ensure that the sides are firmly attached to the bottom. To attach I used a little glue at the bottom of each of the side pieces and clamped each piece to hold the sides firmly to the bottom. I then used a nail gun and some thin nails to ensure these pieces would be firmly attached. Slip the handle in one of the drilled holes in the side and repeat for the other side.
I then used the nailgun again and put a single nail in each side of the 1″ front and back pieces, this will help to ensure that the handle stays secure in between the sides.
Slide the separator pieces into each other and drop them in, and lastly screw in the opener into one of the sides! Congrats on your new wooden 6-pack holder!