For her birthday, I gave Sara a good-for-one-project coupon.  A while later, she redeemed it for a rack she saw online that would hold all the gear it takes to participate in roller derby bouts.

I sketched out a template to use on paper, then did my best to transfer it to some cheap plywood.  It came out okay, but I wasn’t getting straight, clean lines with my jigsaw.  With some re-jiggering, I sketched out a design in Illustrator that was slightly smaller so that I could then cut the side arms out on the CNC machine.

Using my tetris skills, I was able to arrange the parts out so that I could cut all the parts I needed out of one sheet of 2’x4′ plywood.  This way, I could knock out four racks from one sheet of expensive birch ply.

Coated the whole thing in tung oil, then cut logo decals on the vinyl cutter.  The smaller ‘wrecker’ emblem logo was too complex for vinyl, so I headed over to Schenk’s to laser-engrave the logo into a disc that would fit into a pocket that was carved out by the CNC.  This way, if Sarah is promoted into one of the top-tier leagues, the emblem can be replaced with her current league logo.