Mountain View Wood Works

Mountain View Wood Works

Where Old World Craftsmanship and Technology Meet

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This medallion or ornament rack is designed to be shipped broken down and as light weight as possible but still provide excellent strength. The rack may be used as is, painted or stained.

Below are pictures of the assembly process.

	The first step is to put a washer and nut on one end of the all thread rod. Then push the rod through one arm. Next slide one long spacer on each end and a short spacer in the middle. This picture shows only one arm but you will need to install two as shown later on.
	Here you can see the second layer has been installed. The first layer should have two arms installed just like the second layer.
	This picture shows the arms (except for the first layer) all installed. Notice that the center all thread rod goes through each arm but the outside rods only go through every other one. Install a washer and nut on top of the three rods finger tight at this time.
	Notice I have installed the forgotten second arm on the bottom and started to install the all thread rod and spacers on the arms that were skipped in the first step
	Now I have installed the all thread rod through the second arm, added another long spacer and pushed it to just go through the third arm. I will continue to add spacers and push the all thread until I get to the top. Then I will install a washer and nut and again, finger tighten.
	I have now installed all of the spacers and pushed the all thread rod through the top most arm. Now I will install the washer and nut. Remember, finger tighten only at this time.
	I have completed both sides and the nuts are tightened only finger tight at this time.
	Notice how the spacer is NOT seated in the recess. Be sure to move all spacers into the recess before you snug the nuts on the top. You do not need to tighten the nuts a lot. You will cause the parts to bow if you over tighten.
	Now I have moved the spacer into the recess and can proceed .
	I have now positioned the rack on its bottom and am using the base block as a square to make sure I have the two sides at 90* to each other. Once I get it into position, I will tighten the nuts and recheck. Pliers or wrenches will make the tightening much easier but since we all have lasers, you can cut a wrench from 1/8" baltic birch and use that. I will post a .cdr file with the wrenches for you to use at the bottom.
	I have applied some wood glue to the wooden spacer blocks and will install them on the base.
	I have positioned the spacer block on the bottom. Repeat on the other side and let the glue setup. The purpose of these two spacer blocks on the bottom is to give the lazy susan a smooth surface to mount to.
	Both wooden spacer blocks have been glued to the bottom.
	I have now placed the lazy susan bearing on the bottom of the rack and made sure I put the side with a large and small hole next to the rack. Center this up by eye on the four arms. Then install the 1" long phillips screws into the arms with the spacer blocks only at this time. Be sure to hold tight, clamp or wait for the glue to dry or you will break loose the spacer blocks.
	In this picture I have put the rack on its base and have added the last two wooden spacer blocks to the top of the arms that didn't get a spacer block on the bottom. The purpose of these two blocks is to prevent the 1" screws from sticking through the arms as well as giving the rack more strength at the base.
	After the glue has setup on the top wooden spacer blocks you can install screws from the bottom into those arms.
	Flip the rack back over so the bottom is down and place on the base. Next install the four 1" screws as shown. DO NOT OVER TIGHTEN the screws in a MDF base. You will strip the wood. If you like, you can put a few drops of wood glue into the holes to increase the strength of the threads. This is optional and on my racks I have not done this.
	Now your rack should like like this. Now is the time to make sure it is square and make any adjustments. You can make sure it is square by measuring from arm to arm and making them all the same or close to the same. Then tighten the nuts so the arms will not move when the rack is spun.
	Next install all 80 hooks. Look at the end of the instructions for the tool I developed to make installing and aligning the hooks easy. You will cut the tool on your laser. Be sure to NOT OVERTIGHTEN the hooks. Screw them in until the shoulder touches the arms and then back them OUT until the L part of the hook is point straight up. If you snap off a hook, it can be replaced.
	Your rack is complete and ready to hang your ornaments on. Let me know if you have any trouble understanding these instructions. You can email me by clicking on this link Ed Lang