Instructables
Picture of Build a Hanging Shelf System
PictureRail.jpg

This modular, attractive and easily configurable shelf system can be built nearly entirely using readily available parts and materials from any big box hardware store. The locking collars can be found online. Follow these, simplified steps and you can build something similar, of your own design, in a weekend of effort. The companion video gives a better idea of the steps and the tools needed. And even though I have a shop full of sophisticated tools, this entire shelf can be built with hand tools and a power drill. Just not as easily. :-)

 
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Step 1: Design, then Gather the materials

Picture of Design, then Gather the materials
Trex.jpg
AlumTubing.jpg
AlumBar.jpg
Bolts.jpg
Collar.JPG

Look at the empty wall where you want the shelf and picture how you would like it configured. It's best to keep the longest shelf to less than 36". I found the Trex material will sag somewhat with longer spans. If you are hanging the shelf from a picture rail, the spans between the poles are not critical. However, if you are using lag bolts to attach into studs, then you will need to use multiples of 16 inches, and determine where your first pole will be located on your wall, and work out the rest from there. Rough out a sketch and calculate the lengths of tubing, flat bar, and Trex board you will need. You can then count the number of bolts, nuts, and collars needed.

The tubing can be 1" or 7/8" in diameter. It's best to get plated (shiny pre-polished) tubes if you can find them. If not, you can pick up 1" unpolished tubing at a Home Depot or Lowes. You will need the corresponding locking collars for the diameter you choose. They can be bought online. such as here: http://www.climaxmetal.com/standard_set_screw_col... Or, if you have the tools and inclination you can make them yourself for far less cost. In a true cost saving move, you can drill holes through the tubes at the exact right spot and use pins to hold the shelves in place. This is trickier since you have no adjustment afterward, but very cheap.

Parts:

Trex decking lumber 2x6

1/2" x 1/8" Aluminum flat bar

1" or 7/8" Aluminum tubing, plated is best

Correct set screw locking collars for the tubing

1/2" x 3" Carriage bolts and nuts (Picture Rail version)

1/2" x 5" Lag bolts (Hard mounted version)

Over-the-door style coat hooks (optional)

Tools:

1/2" bullet point drill bit Dewalt

Spade bits sized for locking collar and tubing

Hack saw/Band saw

Circular saw/Table saw

Drill press/Power drill and vice

Files, sand paper, utility knife, measuring tools, try square

Skylinc5 months ago

Looks amazing!!