Saw Rack French Cleat - Self Assembly

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Updated Tue Oct 31 2023

Modular saw rack made with friction fit mitre and tenon joinery for glue and fixing free assembly. Part of a series of 8 tool free French Cleats that I cover how to build in the linked Youtube video. Click my profile link to find the others.

1 hr 30 min

Advanced

Cleats

Files Included (15)

Pull Saw Rack Bracket (Left) 15mmED 2.5inFace.svg
4 kB
Pull Saw Rack Bracket (Left) 15mmED 3inFace.svg
4 kB

Pull Saw Rack Bracket (Left) 15mmED 60mmFace.svg

4 kB

Pull Saw Rack Bracket (Left) 15mmED 80mmFace.svg

4 kB

Pull Saw Rack Bracket (Right) 15mmED 2.5inFace.svg

2 kB

Pull Saw Rack Bracket (Right) 15mmED 3inFace.svg

2 kB

Pull Saw Rack Bracket (Right) 15mmED 60mmFace.svg

2 kB

Pull Saw Rack Bracket (Right) 15mmED 80mmFace.svg

2 kB

Pull Saw Rack Insert (Angle) 14.8mmED.svg

1 kB

Pull Saw Rack Insert (Back 6 Bay) 14.8mmED.svg

16 kB

Pull Saw Rack Insert (Front) 14.8mmED.svg

2 kB

Pull Saw Rack Insert (Middle) 14.8mmED.svg

3 kB

Pull Saw Rack Insert (Top) 14.8mmED.svg

1 kB

saw back new.svg

16 kB

saw front new.svg

2 kB

Materials

15mm Ply (or similar see instructions)

Spoil board

Reference board + Shaper tape

Double sided tape

35mm Dowel (or similar)

Cloth tape (to wrap dowel)

Sand paper

Tools

Shaper Origin

6mm spiral upcut bit (or similar)

Mitre saw/Table saw/Hand saw (for cutting dowel)

Instructions

More complete description of how to build is in the linked Youtube Video (use chapters to jump to it). 1. Determine which Left/Right brackets you should use based on the size of your cleat face (60mm, 80mm, 3", 2.5"); 2. Potentially make SVG adjustments* if your ply is not 15mm (14.8mm real world thickness). Mortices are sized at 15mm wide and 14.8mm tall. Experiment with offsets to see what works with the thickness of ply material you have. I used a 0.1mm offset for internal mortices to ensure tight fit; 3. The back piece is sized to hold 6 saws, this can be increased or decreased by adjusting the SVG*; 4. Cut a front, top, angle inserts for each bay; 5. Cut middle inserts for one less than number of bays; 6. Cut dowel rod to fit bay; 7. Wrap dowel rod with cloth tape; 8. Sand all parts; 9. Push fit all the parts together; 10. Optionally cut 16mm plugs to lock saw rack only your cleat. * I cover the basics of SVG adjustment in the Youtube video. Note bracket dimensions assume your wall cleats are made with 3/4" (18mm) ply