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1. Trace the horizontal location for each shelf using a 4-ft. level as your guide. Use a stud finder to mark the locations of the studs and lightly press masking tape over each one. If you don’t have a string line, use a long straightedge and mark the wall with a pencil. Check your marks with the 4-ft. level.
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2. Cut the door blank lengthwise after clamping a straightedge guide to the door. Be sure to use a 40-tooth carbide blade for a smooth cut.
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2. (cont)
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3. Measure the space between the outer veneers of the door and cut cleats from a 2x4 to this thickness. Our measurement was 1-3/32 in. Use straight, dry lumber for cleats.
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4. Predrill 1/4-in. Dia. Holes at the stud locations after you cut the cleats to length (the measurement between the end blocks of the door half). Hold the cleat to your line on the wall and drill into the stud with a 1/8-in. bit. Using a wrench, install one lag screw into each stud until it’s tight. Use 1/4-in. x 3-1/2 in. lag screws. Each cleat must be straight as an arrow.
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5. Cut away the corrugated cardboard cores at least 1-1/2 in. from the cut edge. Scrape away the glue carefully without gouging the wood surface.
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6. Dry-fit the shelf to make sure the blank fits over the cleat. Check the backside of the shelf and scribe it to the wall if necessary. Use a block plane or sander to remove material from the back edge for a tight fit.
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7. Apply glue to the top of the cleat and the inside bottom edge of the door blank. Slide the shelf over the wood cleat.
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8. Nail the shelf to the cleat using a square as your guide. Start at the middle and work your way to each end. Use 1-in. brad nails spaced 8 in. apart.
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9. Build shorter shelves by cutting the shelf to length. Glue a filler block flush with the end and nail each side with small brad nails.
Copyright ©2005 Home Service Publications, Inc.
I want to use this method to build several shelves in a nook I have. I would be using 3 walls to anchor the shelf, not just one. The nook is 15" deep, so do you think that by using 3 walls I could accomplish building a shelf that was 50" wide, 15" deep and could hold a decent amount of weight (say a lamp and a toy box ,or a shelf of books)?
I would not place anything that is heavier than pictures. This design does not offer much support for heavy objects.
does anyone know how much weight this can hold? I want to use this method for a shelf of books... I read the article, but I am not sure if it is strong enough to hold up so many books...