G DAY GUYS!

WE RE AL IMO We absolutely loved it and knew this is what

we wanted to be doing. Since that day we ve
We are proudly self-taught, furniture- been chipping away at our dream of building
makers, business owners, designers and furniture by the sea. We can say with pride
stylists. that we now have a thriving furniture making
business that is always booked out at least six
DIY RUNS IN OUR DNA months in advance.

We started Al and Imo Handmade in 2016 We 100 agree that what you learn should be
because we couldn t afford the furniture shared which is why we ve created these plans
we loved. Although we didn t have to for you.
money the buy what we wanted, we had
the time and the desire to figure out how We look forward to seeing your creations.
to make it ourselves. We built our first bed
on a Sunday in our inner-city, share-house HAPPY MAKING!
carport with carpentry tools and no plan. AL IMO
THE PROJECT
WHO IT'S FOR

THE DESIGN

PREPARATION

SHOPPING LIST

CUT LIST

TOOL LIST

CONSTRUCTION

TIMBER PREP

BUILD

FINISHING

BONUS
CUSTOMISATION
5 7 BOARD RACK

This surfboard rack has been a long time in

the making and we've finally ticked it off
our list of things to do!

We decided to round the edges which

we've provided instructions for - it's a little
tricker so definitely worth having a go if
you want to challenge your woodworking
skills.

If you want the quick and easy way, skip

the routing and just go with the straight
edges.
TIMBER HARDWARE

8 10 GUAGE PHILLIPS HEAD TIMBER

WE USED TASSIE OAK FOR OUR
SCREWS
BUILD AND WE'VE ADDED
12 20MM
ENOUGH LENGTH TO THE BELOW
22 30MM
MEASUREMENTS TO ALLOW FOR
2 50MM
CUTS. FOR A BUDGET OPTION YOU
CAN USE PINE PLY.

BUGEL HEAD BATTON SCREWS

6 75MM
430MM WORTH OF 12MM X
1200MM PLY

MOST HARDWARE STORES WILL

STAPLES
SELL SMALL CUTS OF PLYWOOD
12MM

7M WORTH OF 40MM X 45MM

HARDWOOD
MATERIALS
CHECK THE CUT LIST ON THE
NEXT PAGE FOR REFERENCE. WE YOGA MAT

USED 90MM X 45MM HARDWOOD PVA WOOD GLUE

AND RIPPED IT IN HALF. SANDPAPER

TIMBER SEAL - WE USED FIDDES

2 5M WORTH OF 15MM X 120MM HARDWAX OIL

WE USED SOME OLD FLOOR

BOARDS WE HAD LYING AROUND.

2 4M WORTH OF 35MM DOWELL

WE USED TASSIE OAK HARDWOOD
DIY SURFBOARD RACK

PLY BASE
1 12MM 1200MM X 430MM BASE

YOGA MAT OR THIN RUBBER

1 1200MM X 10MM LINER

HARDWOOD
2 40MM X 45MM 1500MM FRONT UPRIGHTS
2 40MM X 45MM 13 0MM BACK UPRIGHTS
2 40MM X 45MM 435MM BOTTOM RAILS

1 15MM X 120MM 11 3MM FRONT RAIL

1 15MM X 120MM 1213MM BACK RAIL

35MM DOWELL 3 0MM PEGS

TOOLS

TAPE MEASURE
CARPENTERS SQUARE

BUILDERS SQUARE
PENCIL
STANLEY KNIFE
DRILL DRILL BITS
IMPACT DRIVER
CIRCULAR SAW RIP GUIDE DROP SAW
STAPLE GUN HAND STAPLER
HOLE SAW 35MM ATTACHMENT
CLAMPS

SANDER OR SANDPAPER

PROTECTIVE GEAR

SAFETY GLASSES
EAR PROTECTION

OPTIONAL
ROUTER BULLNOSE BIT IF ROUNDING EDGES
STEP 1
SAND YOUR TIMBER SMOOTH TO 120 GRIT

STEP 2
MEASURE MARK AND CUT YOUR TIMBER TO LENGTH USING CUT LIST PROVIDED ABOVE
REMEMBER TO MEASURE TWICE CUT ONCE

STEP 3

CHECK ALL OF YOUR EDGES WITH A CARPENTERS SQUARE YOU WANT THESE CUTS TO
BE PERFECT BEFORE STARTING YOUR BUILD
STEP 1

CUT A 14MM X 14MM CHECK OUT IN THE BOTTOM RAILS

STEP 2

MEASURE AND CUT A 1 ANGLE

STEP 3
MEASURE AND CUT A 1 ANGLE IN THE FRONT UPRIGHTS
STEP 4
MEASURE MARK AND CUT YOUR BACK UPRIGHTS DIAGONALLY FROM THE BACK EDGE
STEP 5 OPTIONAL
IF YOU WOULD LIKE TO ROUT YOUR EDGES TO GIVE IT THAT SILKY SMOOTH LOOK LAY
YOUR WORKPIECE DOWN AND MARK YOUR EDGES WHERE THEY WILL JOIN

NOTE THIS STEP IS TRICKY NOT EASY FOR BEGINNERS

USING YOUR ROUTER BULLNOSE THE EDGES TIP TEST ON A SCRAP PIECE OF TIMBER
FIRST
STEP 6
USING 30MM SCREWS JOIN BOTTOM RAIL TO BACK UPRIGHT

USING 50MM SCREWS SKEW JOIN BOTTOM RAIL TO FRONT UPRIGHT

TO JOIN
MARK COUNTER SINK GLUE PILOT HOLE SCREW WIPE EXCESS GLUE

STEP 7

JOIN BACK UPRIGHT TO FRONT UPRIGHT

TO JOIN
MARK COUNTER SINK GLUE PILOT HOLE SCREW WIPE EXCESS GLUE
STEP 8 OPTIONAL
USING YOUR ROUTER BULLNOSE THE OUTSIDE EDGES

NOTE THIS STEP IS TRICKY NOT EASY FOR BEGINNERS

TIP TEST ON A SCRAP PIECE OF TIMBER FIRST

CAREFUL OF THE COUNTERSINK HOLES
STEP 9
SAND ALL SIDES TO A 120 GRIT FINISH MAKING SURE ALL EDGES ARE FLUSH AND NO
SHARP EDGES
STEP 10
ON YOUR FRONT RAIL MARK YOUR CENTRES DRILL PILOT HOLES

TIP I USED A DOWELL JIG TO MAKE SURE HOLES ARE DRILLED STRAIGHT

USING A 3 MM HOLE SAW DRILL HOLES INTO YOUR PIECE

CHECK THAT YOUR 3 MM DOWELL FITS TIGHTLY INTO THE HOLES

STEP 11
MARK OUT YOUR SCREW PLACEMENT ON BACK RAIL AND COUNTER SINK 10MM FOR TOP
AND BOTTOM SCREWS AND 14MM COUNTER SINK FOR CENTRE SCREWS

GLUE AND CLAMP FRONT RAIL AND BACK RAIL CENTRE TO CENTRE

PILOT HOLE AND SCREW 20MM SCREWS AROUND EDGES

ONCE JOINED CLEAN UP TOP AND BOTTOM EDGES WITH EITHER A SANDER OR PLANER
UNTIL FLUSH

SAND PIECE TO 120 GRIT REMOVING SHARP EDGES

STEP 12 OPTIONAL

USING YOUR ROUTER BULLNOSE THE TOP AND BOTTOM EDGES ON THE FRONT ONLY

NOTE THIS STEP IS TRICKY NOT EASY FOR BEGINNERS

TIP TEST ON A SCRAP PIECE OF TIMBER FIRST

STEP 13
CUT YOUR DOWELL TO 3 0MM LENGTHS X MAKING SURE YOUR CUTS ARE SQUARE

USING HAND PAPER CLEAN UP CUT EDGES

STEP 14

GLUE THE INSIDE EDGE OF YOUR FIRST HOLE AND BASE OF ONE POLE

FIT INSIDE USE A RUBBER MALLET OR HAMMER AND BLOCK TO ENSURE BASE IS
TOUCHING THE BACK PIECE

USING A SQUARE CHECK POLE IS SQUARE VERTICALLY AND HORIZONTALLY

PRE DRILL STRAIGHT MM OR MM DRILL BIT THROUGH CENTRE HOLE MARKED ON THE
BACK RAIL

DRIVE A MM BUGEL HEAD BATTEN SCREW THROUGH THE BACK

REPEAT WITH REMAINING POLES CHECKING THEY LINE UP AS YOU GO

STEP 15

MEASURE 13 MM DOWN AND MARK BOTH SIDES

SANDWICH RAIL BETWEEN SIDE UPRIGHTS USING CLAMPS TO HOLD IN POSITION

ONCE YOU ARE HAPPY WITH WHERE YOUR PIECE IS SITTING SQUARE NO GAPS IN THE
FRONT

PILOT HOLE AND SCREW THROUGH ALREADY MARKED COUNTER SINK HOLES USING
40MM SCREWS
STEP 16

CUT YOGA MAT OR RUBBER TO 1200MM X 10MM

TIGHTLY WRAP AROUND PLY AND STAPLE IN PLACE EVERY 0MM ALONG EDGE

STEP 1

PLACE YOUR BASE IN BETWEEN YOUR UPRIGHTS MAKING SURE BASE SITS FLUSH INTO
CHECKOUTS

CLAMP YOUR PIECES TOGETHER

MARK COUNTER SINK PRE DRILL AND SCREW BASE TO UPRIGHTS USING 30MM
SCREWS
STEP 1

HOPEFULLY YOU ARE NOW LOOKING AT A FULLY CONSTRUCTED SURFBOARD RACK

STEP 1

CLEAN UP ANY REMAINING GLUE SHARP EDGES OR ROUGH AREAS WITH 120 GRIT
SANDPAPER

WE REMOVED THE BASE TO MAKE IT EASIER TO SEAL THE TIMBER AND REPLACED ONCE
IT WAS DRY
STEP 1

IF YOU WOULD LIKE TO PUTTY UP THE SCREW HOLES NOW IS THE TIME SAND
EXCESS PUTTY OFF WHEN DRY

STEP 2

SEAL YOUR PIECE WE USED FIDDES HARDWAX OIL WHICH PROTECTS THE TIMBER
LEAVE THE PIECE OVERNIGHT TO DRY

STEP 3

RE FIX BASE TO TIMER STAND

FILL WITH YOUR QUIVER BRAH

YEWWWW CELEBRATE YOUR HARD WORK WITH A WELL EARNED SURF YOU DID
IT
YOU CAN MAKE THIS BIGGER OR SMALLER TO HOLD MORE OR LESS BOARD ALL YOU
NEED TO DO IS ADJUST PLY BASE MEASUREMENTS RUBBER YOGA MAT BACK RAIL
AND QUANTITY OF POLES
GOOD DESIGN GOOD PEOPLE
AL AND IMO HANDMADE