Special Note: In the following steps I describe how I removed the lip from the flanges, if you'd rather not have to do this I've learned that Simplified Building can bore out the fittings for you (additional cost per flange).
Step 1: Parts List
x3 - 10ft 1" galvanized pipe | Home Depot
x3 - 1x12x8 | shelves | Home Depot
x2 - 1x6x8 | header and footer | Home Depot
x3 - 2ft 3/4" threaded rod | clamp assembly | Home Depot
x6 - 3/4" bolts | clamp assembly | Home Depot
x6 - 3/4" flat washers | clamp assembly | Home Depot
x60 - 3/4" screws | attach flanges to shelves | Home Depot
Step 2: Remove the Flange Lip
I forget the exact size of the bit (after the 9 flanges it was useless and thrown away) but it just fit inside the flange.
The flanges were screwed down to the table to keep them secure during drilling
note: the following action likely voids any guarantee or warranty the Kee Klamps have.
Step 3: Cut the Pipe
The length of the pipe depends on how high your ceiling is and how long your threaded rod is, I cut mine about 9" short of the ceiling, with 2' of threaded rod this gives me plenty of playing room.
You don't want to pipe too long or short - too long and it will make adjusting the clamp difficult or impossible, too short and you wouldn't be able to clamp the shelf between the ceiling and the floor.
Step 4: Clamp Assembly
Step 5: Drill Holes in Shelves
I clamped the shelves together and marked where I wanted the holes on the top shelf. Leaving the shelves clamped together and using a standard bit (1/4" I think) I drilled a hole through all the shelves. I then un-clamped the shelves and used the smaller hole as a guide for the hole saw, so the holes ended up in the same place on all three shelves.
Using the hole placement on the shelves as a guide I marked where the flanges needed to be on the header and footer.
Step 6: Test Assembly
Step 7: Assembly Notes
Step 8: Sanding
Step 9: Final Assembly
The assembly followed what was described in step 7:
1. Pipe was placed in footer flanges
2. Bottom shelf flanges were slid on
3. Bottom shelf was put in place, roughly where I wanted it
4. Middle shelf flanges were slid on
5. Middle shelf was put in place, roughly where I wanted it
6. Top shelf flanges were slid on
7. Top shelf was put in place, roughly where I wanted it
8. Header was put in place, the unit was clamped lightly
9. Final adjustments were made to the placement of the header and footer, so the pipes are straight
10. Final hight and level adjustments were made to each shelf, make sure the set screws are TIGHT
11. Clamped the shelf tighter in place, it's not moving, don't make it too tight
12. Flanges were attached to the shelves with 3/4" screws
It might seem like a lot but it's very simple and fast. I emphasize the order because I found it was the easiest way.
If you really want it here is the SketchUp file is attached.
Step 10: Notes
- Galvanized pipe is dirty because of the oil that is on it, youâ€™ll want to clean it off after cutting it to length, dish soap and water worked well.
- The Home Depot grade of galvanized pipe may not be â€prettyâ€ to some people. You could use aluminum pipe or prettier galvanized pipe but itâ€™s a bit spendy and I like the industrial look; fence post is probably to flimsy for this project.
- The table saw and metal cutting blade I used worked but it binds easily, a chop saw would work better.
- You want to tighten the clamp mechanism pretty tight, just not too tight as putting a hole through your ceiling would defeat the purpose of this shelf.
- I didnâ€™t cut the 2ft threaded rod, about 1-1/2â€ is inside the top flange the rest is inside the pipe. You want to make sure that there is a decent portion of the rod in the flange and the pipe to alleviate the possibility of it slipping out.