Easy Metal Project. - Sorting Shelf-

About: Just a fellow who want's to learn new tricks and skills.

Hi

Some viewers on my youtube channel, has commented that i should make easier projects.

This instructable is one, that i found to be easy, usefull, and to fun to make.

All sorting shelfs at my local hw-store we're made from plastic or very thin steel and we're somewhat crappy... Decided to build my own to get one that i wanted.

I used surplus materials that i had in my shop, so its price for me was about 15€. ( paint, welding rods, boxes..)

Plastic boxes are bought from local Hw-store, 0,50 cent / each. ( Finnish people can found similar ones from Kärkkäinen. )

I used miter saw for some cuts, but all cuts can be made with angle grinder too. ( example )

Video tutorial:

Materials:

Feets.

2 pcs: 30 x 30 x 1.5mm box section, 500mm long

1 pcs: 30 x 30 x 1.5mm box section, 470mm long.

Framing:

5 pcs: 20 x 20 x 3mm L-profile ( angle iron ) 470mm long.

2 pcs: 30 x 20 x 3mm L-profile 720mm long. Both ends are cut to 22.5 degree angle, both to same direction. ( longer side is angled )

2 pcs: 30 x 20 x 3mm L-profile 390mm long. Lower end 66 degree, upper 56 degree. Angles cut to opposite directions.

4 pcs steel sheets. 465mm wide, 212mm long. I used 1,5 and 2mm sheets. ( surplus )

( Bends 10mm lid, 110mm vertical side, 90 ( + 2mm working allowance to vertical side )mm horizontal see the picture )

Bends are made with my diy bending brake, using 3mm radius.


Tools:

Angle grinder. ( cut off wheels, flap disc )

Welder. ( i used cheap Telwin force 145 stick welder. ) 1.6 or 2mm welding rods. ( used Esab ok 73.15 )

Step 1: Making the Stand / Feets..

Feets are made from 30 x 30 x 1.5mm box section.

Cuts are made straight, to dimensions 2 pcs 500mm and one 470mm long piece.

I clamped parts together right angled. Placing 470mm wide piece to the middle, so that inner widht is 470mm.

Tack welded parts together from both sides, small weld to each corner. ( top and under )

Smoothened welds with angle grinder equipped with flap disc ( weared out 40 grit )

Then i tack weld pieces off 3mm angle iron to hide the ends, these also makes ends thicker and therefore its possible to get stong enough threads to them. ( for the adjustable feets )

At this point, i weld thicker angle irons and box sections together.

That connects both parts together, with the same welds.

When pointing weld more against thicker material, then it doesn't weld so easily through, even that 1.5mm box section is somewhat thin.

Its good to let piece cool down a little after each weld, then it doesn't melt through.

I used 1.6mm rod and 50A current ( can't say is the scale of my welder accurate or not )

After welding i cleaned the welds with angle grinder.

Drilled 5,2mm hole to every corner and threaded holes with M6 tap. M6 screws works as a adjustable feet.

( i have tile flooring on my shop, so i didn't need to use rubber pads under the feets. to secure floor from scratches )

Step 2: Framing..

Framing is made from 20 x 20 x 3mm and 30 x 20 x 3mm angle iron.

20 x 20 x 3mm parts are cut to lenght 470mm. Same as the inner widht of the feets / stand.

20 x 30 x 3mm parts are cut to lenght 720mm, both ends are cut to 22.5 degree angle. ( angles in same direction, wider side is angled. )

470mm long angle irons are tack weld between 720mm pieces with 100mm interval. Remeber to place 720mm long pieces mirrored, wider side in from both.

First one is placed 300mm from the lower end, all others with 100m distance to each mark. ( 100mm distance from the corner to the same corner to another angle iron. )

When all parts were tack weld on their right placement, i tilted them to the 22.5 ( or 77.2, depends from the measuring side) degree angle. ( Remember to check that structure is right angled after you have tacked the first parts )

Angle iron is raised above the sides, it might be look neater if those would be placed lower, but there is a reason why i did it this way. This can be seen at the end

Then i weld parts together. Used 2mm rod and 70A current ( can't say is the scale in my welder accurate or not )

Cleaned the welds with angle grinder, and weld all parts togehter. After tack welds, make sure that everything is nice, then weld structure together.

Step 3: Shelfs..

Shelfs are made from 1.5mm and 2mm thick sheets. ( upper shelf is thinner because i ran out of 2mm sheet)

I cut the parts to the size 465 mm x 212mm, i used scribe for marking and cut next to the line. Its more accurate way than trying to cut on top of the line. Remember to cut from to right side of the marking.

Removed the coarse with angle grinder using flap wheel.

Then i bend the with my diy brake, using 3mm radius.

Sides: 10mm lid, 90mm verical, and 112 mm horizontal.

Step 4: Assembling the Shelfs..

Assembling the the selfs is very easy task.

Shelfs are 5mm shorter than the internal widht of the frame, this leaves 2.5mm room for the welds in the angle irons.

Shelfs are tack welded from the frame, and the welds and working allowance is smoothened with angle grinder.

Then another shelf is placed on top of the previous one. This gives strong enough and nice looking joining.

Step 5: Paint..

Clean welds with flap wheel or brush, remember not to grind whole weld away.

Wipe with cleaner, thinner or xylene, and paint.

Step 6: -- Finished --

Structure is now finished.

And this explains, why angle irons are tilted so that those "pump" above the surface level of the sides.

Lower one supports the shelf on top of it. Each shelf is supported with angle iron under it. This "locks" the shelf on its place and carries most of the weight, then there's no need to make larger welds for attaching the shelfs.

Tilting brings it little more closer to the outer end of the shelf and gives better support.

Also, welding is easier, stucture is strong enough, even if only this "pumped" out corner is weld.

Works with boxes, or storing rods, axles.... etc.

Boxes that i used are 80mm high and lenght of the bottom is 90mm.

Measures are taken so that those boxes fit nicely. So, remember to adjust measures suitable for your use.

Thanks for checking this out!

Video tutorial shows the process:

Regards

Tuomas Soikkeli

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