A cowboy hat can give you a look which stands out. However to properly maintain your cowboy hats, you will need more than a basic hat rack. A specially designed rack will ensure that your hat has the proper support to maintain its shape when not on your head, allowing you to enjoy it for years.
Constructing the Base
Draw the shape of your base on the wood plank with the pencil. You can make a simple rectangular shape, or you can be more artistic. Visit the Resources below for stencils in the shape of a boot or Texas, as well as a template for the racks.
After drawing a shape, cut around the outside of the pencil lines with the jigsaw. It is better to leave wood outside the lines than accidentally cut too far in.
Sand the edges of the rack down to the pencil lines to create a smooth edge.
Drill into the base where the hat racks will be placed with a bit large enough to fit the jigsaw blade in the resulting hole.
Expand the hole to a three-quarter inch square with the jigsaw.
Making and Mounting the Racks
Draw the neck of your rack by making a rectangle one inch wide by five inches high on the wood board in pencil.
Draw a "U" shape atop one end of the neck that is eight-and-one-half inches tall and nine-and-one-half inches wide, creating a rounded "Y" shape. Like the neck, the shape should be at least one inch thick at all times.
Cut the rack out with the jigsaw, again erring on cutting outside the lines.
Sand the rack down until it is smooth and inside the pencil markings.
Use the tenon jig on the table saw to make a one-eighth inch wide, one inch high, cut along all four sides of the bottom of the neck. This will result in a one inch long peg that is in the shape of a square with three-quarter inch sides.
Apply wood glue to the peg, insert it into the hole in the base, and leave to dry.
Stain the rack a color of your choosing.