How to Make a Hat Rack for Baseball Caps

Put on a pair of safety goggles and work gloves. Lay out two full sheets of 3/4-inch thick plywood on a large work table.

Measure one plywood sheet at 5 feet by 8 1/2 inches. Measure two more pieces at 5 feet by 12 inches. Cut the measured pieces of plywood with a circular saw. The 12-inch wide pieces are the side panels, and the 8 1/2-inch wide piece makes up the rear panel of the rack.

Measure and cut two more pieces at 8 inches by 12 inches. These are the rack's top and bottom pieces.

Lay out the five cut pieces of plywood on your work table. Remove any scrap pieces of wood from your work area. Make 10 evenly spaced line markings widthwise on the larger side and rear wood panels, with an L-square and carpenter's pencil. Continue each line on the opposite side of each panel. These lines are markings for the shelving panels.

Apply a thick layer of wood glue to the rear side of each side panel. Place the panels lengthwise onto the rear panel, so they butt up with each of the rear panel's edges. Attach the rear panel to the side panels with several evenly spaced 1-inch framing nails.

Apply a thick layer of wood glue on the top and bottom edges of each side panel. Press the top panel up against the top edge of the panels. Align each side panel so they sit flush with the sides of the top panel. Attach the top panel to the side panels with two to four 1-inch framing nails. Let the wood glue dry for several hours, and repeat this to attach the bottom panel.

Measure the width of the spacing between the two side panels, and the depth of the side panels to where they meet the rear panel. Measure and cut 10 boards according to your measurements. These boards will make up the shelving.

Lay the rack on its back, so the opening is facing upward. Position the first shelf board inside the rack with the bottom edge of the board flush with the line markings on the side panels. Place a framing level on the top side of the shelving board, to make sure it is sitting level with the rack. Attach the shelf board to the rack with two to four 1-inch framing nails, along the outside of the rack. Repeat this to attach all 10 boards inside the cap rack.

Sand the surfaces of your hat rack with fine-grit sandpaper, until each surface is smooth. Wipe away all excess sawdust with a dry washcloth. Apply the desired wood finish to your rack's surface, with a soft-bristled paintbrush.