Introduction: Rustic Farmhouse Style Torched Wood Shelf With Plumbing Fitting Shelf Brackets
This instructable will give you step by step directions to create a Rustic Farmhouse Style Torched Wood Shelf with Plumbing Fitting Shelf Brackets. This shelf is fully functional and can be used in several applications in your home to display decor.
Supplies
Shelf Supplies:
- Wooden board for shelf. (Board size will depend upon the location space and desired finished size of shelf. For the purpose of this project the board dimensions are 9.5"x28")
- (4) 1/2in. black steel pipe floor flanges (packaging pictured for reference)
- (2) 1/2in. x 2in. black steel pipe nipple (packaging pictured for reference)
- (2) 1/2in. x 4 1/2in. black steel pipe nipple (packaging pictured for reference)
- (2) 1/2in. 90° black steel pipe elbow (packaging pictured for reference)
- (8) 2 1/2 in. construction screws
- (8) 3/4in. flat head screws
- spray paint of desired metal finish
- clear coat for protective sealant
- 220 grit sandpaper
- drywall anchors (optional
Tools Required:
- 4ft. level
- standard tape measurer
- torch
- stud finder
- pencil
- pipe wrench (optional)
- impact driver with an 1/8in. drill bit as well as a torx bit, and phillips bit
- shop rags
- nitrile gloves
- acetone or mineral spirits
*table saw may be required if you are cutting shelf board to size yourself
Step 1: Gather Supplies
Shelf Supplies:
- Wooden board for shelf. (Board size will depend upon the location space and desired finished size of shelf. For the purpose of this project the board dimensions are 9.5"x28")
- (4) 1/2in. black steel pipe floor flanges (packaging pictured for reference)
- (2) 1/2in. x 2in. black steel pipe nipple (packaging pictured for reference)
- (2) 1/2in. x 4 1/2in. black steel pipe nipple (packaging pictured for reference)
- (2) 1/2in. 90° black steel pipe elbow (packaging pictured for reference)
- 2-1/2 in. construction screws
- 3/4in. flat head screws
- spray paint of desired metal finish
- clear coat for protective sealant
- 220 grit sandpaper
- Dry wall anchors (optional)
*Note: the length of pipe nipples used in this project can be adjusted based on the desired shelf size. For the purpose of this project, the nipple size reflect a shelf board with the dimensions of 9.5"x28" you will size the pipe nipples up or down accordingly.
Step 2: Gather Tools
Tools Required:
- 4ft. level
- standard tape measurer
- torch
- stud finder
- pencil
- pipe wrench (optional)
- impact driver with an 1/8in. drill bit as well as a torx bit, and phillips bits
- hop rags
- nitrile gloves
- acetone or mineral spirits (not pictured)
*Table saw may be required if you are cutting the shelf board to size yourself
Step 3: Determine Shelf Location
Using a stud finder to find studs, locate studs that will span the length of your shelf. Make a mark with a pencil identifying stud locations.
(In a later step, when mounting the shelf brackets to the wall, you will want to be sure you are drilling the screws into studs to insure the shelf is secure to the wall. Not drilling directly into studs will compromise the overall load capacity of the shelf and risk the brackets pulling out of the wall over time.)
With a level, draw an intersecting line with the stud locations. This will serve as a starting point for mounting the shelf brackets
*If you are not able to hit a stud while installing the shelf brackets ,a drywall anchor and screw (not pictured) will be required.
Step 4: Determine Dimensions of Shelf
With the size of the shelf determined, purchase and or cut board to desired dimensions. If you are wanting a custom length shelf and do not have a saw, many home improvement stores will offer to cut the board for you as long as you supply measurements. For boards that are utilized, either two by material or one by boards will work for your project.
Step 5: Assemble Pipe Fittings to Be Used As Shelf Brackets
- Thread 4 1/2in. nipple into floor flange.
- Thread the 90° elbow onto the 4 1/2in.pipe nipple.. firmly grasp the one end while twisting the 90° elbow. Thread 2 in pipe nipple into other end of the 90°
- Thread the other end of the 2in. pipe nipple onto the second floor flange.
*Note, fittings should be hand tight only, if unable to take apart, use pipe wrench to adjust and loosen.
Step 6: Clean Plumbing Fixture Shelf Brackets
Clean plumbing fixtures with acetone or mineral spirits and a shop rag. Utilize safety procedures by wearing gloves and make sure to have plenty of ventilation in the room that you are working in. Wipe down the entire fixture with the acetone or mineral spirits and allow to dry.
Step 7: Paint Plumbing Fixture Shelf Brackets
Paint plumbing fixtures. Again, be sure there is adequate ventilation while spray painting the fixtures. While painting, note that it is better to apply more light coats than one heavy coat of paint. Follow the manufacturer’s recommendation of the spray paint that you are using. Typically, maintain 12”-18” away from the piece that is being painted and press and release the spray paint nozzle as you go back and forth in a gentle sweeping motion.
Add additional coats of paint for full coverage until desired finish is achieved.
Allow paint to thoroughly dry before handling.
Step 8: Secure Plumbing Fixture Shelf Brackets to the Wall
Once paint has dried, secure the fixtures to the wall using the construction screws, impact driver, and a torx bit (or a the bit to fit the style head of your construction screws). Check to make sure the brackets are level.
( you will want to be sure you are drilling the screws into studs to insure the shelf is secure to the wall. Not drilling directly into studs will compromise the overall load capacity of the shelf and risk the brackets pulling out of the wall over time.)
* If when you measured out your placement of your shelf brackets, you were not able to locate a stud to affix your shelf brackets into, a drywall anchor(not pictured) and screw will be required to be installed at this time. You will do this by first pre drilling your determined holes into the wall, and pounding a drywall anchor into the holes before screwing the bracket into the anchor in the wall.
Step 9: Torch the Wood
Distress wood with a blow torch. Similar to painting, use an even back and forth motion to lightly char the wood that will be used for your shelf. Depending on how dark of a finish you are looking for, allow the flame to char the wood more or less. Complete this process on both sides of the board and all four edges. Be very careful working with an open flame and make sure that all combustibles are clear of the flame’s path.
*you may need to experiment the torching technique on a scrap piece of wood before performing this step on your finished product. Test out going different directions (with the grain and against the grain) as well as the duration you are torching the wood. This will ensure you are getting the desired effect you are looking to obtain for your finished product.
Step 10: Sand and Clean
Allow the wood to cool for a few minutes. Once the wood is cool to the touch, lightly sand the board with 220 grit sand paper.
Wipe down the board with a damp shop rag to remove any excess sawdust.
Step 11: Seal the Wood
Seal wood using a sealer. This can range from high gloss to a matte finish, depending on your preference. If using an aerosol spray sealer, follow the same procedure as painting the fixtures. Always follow the manufacturer’s recommendations for applying the sealer.
Step 12: Determine Shelf Placement
Center the board for shelf on the brackets. Measure each side to ensure there is an equal measurement on both left and right sides which can be adjusted easily by moving the board one way or the other.
Step 13: Determine Hole Locations
Using a pencil, carefully mark hole locations on the underside of the board. Make sure the board does not move as this will skew your hole locations. This is in preparation for pre-drilling holes.
Step 14: Pre-Drill Holes
Remove the shelf from the brackets and drill a small hole using an 1/8” drill bit set at ½” depth in each of the four flange holes. This can be done by taking an 1/8” drill bit, measuring ½” from the tip of the bit down, using a marking or piece of tape as a guide, and drilling this depth in each of the four holes.
Step 15: Attach Shelf
Place the shelf board back up on top of the shelf brackets and line up the predrilled holes with the holes in the floor flange. Using the phillips bit on the impact driver, attach the shelf with the flat head screws into the board through the holes in the floor flange. The shelf is now secure to the brackets.
Step 16: Arrange Shelf With Decor
