LEGO Shaped Floating Shelves Made From Trash | LEGO Display Shelf

IKEA Hack: I Turned an IKEA Shelf from the Trash into a big LEGO bricks Shaped Floating Shelves!

My kids asked me to make a storage for their LEGO builds, or LEGO display shelves... so... I found it logical to make LEGO-Shaped shelves for them, in an unused small niche in their room.

The shelves were built in proportion to real small LEGO bricks! (See further info in the below steps)

I used some nice techniques which worth to watch & learn! Enjoy.

You're welcome to visit my YouTube Channel, and watch my additional different DIY & Woodworking projects.

Supplies

General List of tools I'm using - https://www.itzikdiy.com/tools-list?m=1

Tools in this Instructable:

• Laser level (optional)
• Utility knife
• Sander
• Sanding paper
• Drill Driver / Impact drill
• Sliding miter saw or other saw
• Circular saw
• Measuring tape
• Caliper tool

Materials:

• Small LEGO brick
• Ikea Shelf (LACK or KALLAX)
• Cardboard (for stencils)
• ~4*4cm pine wood profile
• Hoe handle
• Wood filler
• Wood glue
• Wood screws
• 2X color sprays
• Masking tape
• Clear Protective topcoat paint
• Stapler

Step 1: The Video

You can watch the making process, in this video.

Let me know what do you think about the idea 

You're welcome to visit my YouTube Channel, and watch my additional different DIY & Woodworking projects.

Step 2: The Wall Niche

This is a small niche in my kids' room.

It was unused for few years... it's time to use it for these shelves!

Step 3: Annoying Wall...

It wasn't easy to fit the shelves to the wall niche, because unfortunately the walls were uneven / not square (not close to 90 degrees).

It's an old apartment and this is very annoying everytime...

Step 4: Making Shelves' Stencils

The solution for the uneven walls, is to create a stencil using a cardboard.

I cut 3 pieces of cardboard as can be seen in the pictures. I put the bigger piece in the niche and 2 smaller parts pushed to the wall on both sides to fit the wall's angle. Then I connected all of them using a stapler.

Step 5: Marking the Shelf Shape

I took a shelf, which is part of IKEA's shelving unit (Similar to KALLAX, but older model). I found it on the trash on the street :)

I marked the stencil shape on the shelf.

Step 6: Cutting the Shelf

I cut the shelf shape using a circular saw.

Step 7: OOPS... Additional Stencils Required...

Unfortunately, the niche walls have different spaces in different heights that I planned to install the shelves.

I had to make 2 additional stencils and I cut the 2 other shelves

Step 8: Clean Shelves Are Ready

The 3 shelves (with a bit different sizes) are ready.

As you can see, the IKEA shelf isn't made of a solid wood or other type of high quality plywood.

Many of IKEA furniture are made from a material filled with "Hexagonal honeycomb cardboard" (called "Particle- and fiberboard with honeycomb paper filling").

Step 9: Did You Know?

Did you know that many IKEA furniture are made from this Honeycomb Paper Filling material??? 😊

Step 10: Cutting the Floating Shelves' Holders

I cut 12 pieces of pine wood (~4*4cm profile), 4 for each of the 3 shelves.

These will be used as the holders for the floating shelves on the niche.

Step 11: The Advantage of the Honeycomb Paper Filling

As shown above, the IKEA shelf that I used, is filled with a cardboard which is not a high quality material, but in this case, it was an advantage for me. I can just push the cardboard around the shelf, and push the shelf over the shelves' holders on the wall, as you'll see later.

Step 12: Drilling Holes in the Holders

I drilled 4mm holes in the wooden shelf holders.

Step 13: Marking the Holders Positions

I marked the position of the 4 holders, over the shelves and then I copied the positions from the shelves, to the niche.

Step 14: Drilling Holes for the Holders (1)

In order to mark the drilling position on the wall, I started by using the wood drill bit and drilled over the wall (just to mark)

Step 15: Drilling Holes for the Holders (2)

Later, I drilled each hole deeply using a concrete and masonry drill bits, according to 2 wall types I had there.

Step 16: Connecting the Holders for the First Shelf

I pushed wall plugs (rawl plugs) in each hole and screwed a long screw through each holder, to the plug.

Step 17: Making Spaces for the Holders

As shown above, the IKEA shelf that I used, is filled with a cardboard which is not a high quality material, but in this case, it was an advantage for me.

I could just push the cardboard around the shelf, and push the shelf over the shelves' holders on the wall.

Step 18: Initial Testing of the First Shelf Fit

I pushed the first shelf on the brackets, and it was a perfect fit...

Step 19: Connecting the Holders for the Other Shelves

Step 20: Shelves' Holders Are Ready

Step 21: Testing of the Other Shelves Fit

I pushed the 2 other shelves on their brackets, and it was a perfect fit as well.

Now I have 3 regular floating shelves. Let's make them LEGO Bricks!

Step 22: Small LEGO Brick to Big LEGO Shaped Shelf...

As mentioned in the intro, the shelves were built in proportion to real small LEGO bricks!

I took a basic size LEGO brick and measured the sizes using a caliper tool.

(BTW, you can find these dimensions or similar ones, on the internet as well. I didn't think about it back then... 😊)

Step 23: Calculating the Proportions

According to my measurement, these are the LEGO brick dimensions:

- Small LEGO Brick Width ~7.8mm

- Small LEGO Brick stud diameter ~4.9mm

- Small LEGO Brick stud height ~1.9mm

In addition, I had the fact that the IKEA shelf width is ~50mm, so the calculation for the Big Lego Bricks on the shelf, is:

Ratio between Big & Small = 50 / 7.8 = ~6.41

- Big LEGO Brick Width ~50mm

- Big LEGO Brick stud diameter = 6.41 X 4.9 = 31.41mm (the photo from the video shows 30.7mm. It's a mistake but it doesn't matter too much in this case anyway 😊)

- Big LEGO Brick stud height = 6.41 X 1.9 = ~12mm

Step 24: Making the LEGO Brick Studs

As you understand, I tried to be very accurate with the dimensions, so the proportions will look the best.

I was looking for a wood that will fit the diameter of the LEGO studs (~3.4mm) and couldn't find. One day I went to a gardening accessories store, and by chance I saw this wooden Hoe handle. I asked the seller for a caliper tool, and measured the diameter... and it was ~30.5mm along most of the handle.

Good enough? YES.

Step 25: Cutting the Brick Studs

I used my sliding miter saw to cut tens of LEGO Brick studs. (The size is ~12mm as calculated before.)

I felt like I'm cutting a Salami sausage... 😅

Step 26: Sanding the Brick Studs

I sanded the studs using a sanding paper.

Step 27: Filling Holes in the Shelf

The shelf had some holes. I filled them using a wood filler.

Step 28: Measuring the Studs Positions

In order to mark the studs positions on the shelf, I did the same calculation as before.

I measured the distance between the studs on the small LEGO brick and marked them on the shelf in the same proportions.

Step 29: Gluing the Studs

I glued the Brick studs to the shelf using a wood glue. It holds it very strong.

Step 30: Basic LEGO Shelves

Basic LEGO shelves are ready... but there is some more work to do....

Step 31: Painting the Shelves - White

I painted the shelves and studs using 2X spray color.

Step 32: White LEGO Shelves...

Step 33: Marking the Random Bricks

I marked random bricks shapes over the white shelf using a pencil.

Step 34: Random Bricks Marked

Step 35: Masking the Random Bricks

Using a masking tape and utility knife, I masked the places that shouldn't be painted

Step 36: Masked Random Bricks

Step 37: Painting the Shelves - Gray

I painted the masked shelf using 2X Gray color.

Step 38: Most Satisfying Part!

This is the most stressful part, but also the most SATISFYING!

I peeled off the masking tape, from the painted shelf. I was afraid that it will peel some of the paint... but it was PERFECT for me. I didn't expect this result.

It's important to use a high quality spray for such project... and 2X is such.

Step 39: Two Colors LEGO Shelves...

This is the mid result.

Step 40: Second Masking

I masked the places that shouldn't be painted, for the 3rd paint.

Step 41: Masked Shelf

Step 42: Painting the Shelves - AQUA

I painted the masked shelves in the 3rd time, using 2X Aqua color.

Step 43: Peeling Off the Second Masking

I peeled off the second layer of masking tape, from the painted shelf. As before, it went perfect.

Step 44: Final LEGO Shaped Shelves...

Step 45: Painting the 2 Additional Shelves

Initially, I planned to make the 2 additional shelves in both Aqua and Gray colors, as the first shelf.

After I found that it was a very long process, I decided to paint each of them only in one color. One Aqua and one Gray.

Eventually, I'm glad with this decision, because as you'll see later, when the shelves will be installed on the wall, I think that it's more pleasant to the eye in this way.

Step 46: Painting With Clear Protective Topcoat

For a final touch, I painted the shelves with a clear protective topcoat.

Step 47: Installing the Shelves

I pushed each shelf to it's position (I remind you that each of them has a bit different size due to the uneven walls in the niche.)

I connected each shelf only with one screw from the bottom corner. It was enough to hold it in place. (The shelves aren't designed to hold heavy weight, but only LEGO builds.)

Step 48: The Final RESULT - Shelves Installed

Step 49: Arranging My Children's LEGO Creations

Before surprising my kids with the result of these shelves, I arranged all of their LEGO builds creations on the shelves.

How did they react? It's on the video...😊

Step 50: The Shelves Populated With Lego Creations...

It was a very long project, but I'm so happy with this result!

What do you think?

Step 51: The Video

You can watch the making process, in this video. How did my kids react to the result? It's on the video as well...😊

Let me know what do you think about the idea 

You're welcome to visit my YouTube Channel, and watch my additional different DIY & Woodworking projects.