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SKILL LEVEL: Beginner
TIME COMMITMENT: 2–3 hours
Here's what you'll need to get started.
Optional Equipment/Tools
WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER'S MANUAL.
Cut a 4" piece off the 24" long side. You should have a 4" x 24" piece. This will be the back side. Then cut 2" off the large 8" x 24" to make it 8" x 22". This will be the base.
Weld the base to the back side, centered 1" from each side and 1" from the bottom. You should have 3" of the back side on top of the base and 1" below.
Mark one of the 1/4" round bars at 8” and 31". These will be bend points.
Place 1/4" round stock in vice at the 8" mark, heat with propane torch and bend 90 degrees. Then move the bar to the 31" mark and make a bend again at 90 degrees, parallel to the first bend.
Trim excess of the bar to fit against the back side. Mark and trim the bent 1/4" round bar to fit the base against the back side. Line up the bent bar so the long front edge is in line with the front of the base.
Mark the two side legs where they meet the back side, then mark where the bent bar meets the back piece 3/4" from the top edge.
Drill 3/16" hole at that mark. This will be plug welded to the bar from behind.
Cut three pieces of the drop-off 1/4" round bar to 2-1/8” long and deburr.
Make a mark at 11" along the front edge of the base and the center of the bar.
Weld support bars. Weld a 2-1/8" support bar at that 11" mark and at each front corner.
Set bar on front stand-offs, spot weld to the back side from front and plug weld the bar from behind.
Spot weld tops of three supports to main bar.
Take another 1/4" x 48" round bar and cut it in half.
Mark 4" from one end on each of those two 24" bars.
Place in vise at that 4" mark, heat and bend 90 to 100 degrees. This will form the bottom hooks.
To create the top hooks, cut two 4" pieces off another 1/4" round bar and deburr.
Weld one of the 4" pieces to each of the 20" long bars, 3" from the top of the bar at a similar angle as the bottom hook. This will give you four hook locations. Depending on your needs, you may wish to add more hooks or use less.
Tip your shelf on the back side. Make a mark on the underside 1" of the back side at 6-1/2" and 17-1/2".
Weld the long hook bars on each mark with the “hook” up. (If mounting on ribbed steel siding, weld on the rear of the back side of the shelf.)
Paint Miller Blue! Of course, I always go a little overboard … Before painting, I hole-sawed and flared some holes in my shelf base. It lightened it up and added some ventilation.
Drill two or three holes along the top of the back side and mount to wall.
Feeling inspired? Check out our project page for DIY welding projects, including step-by-step guidance, videos and downloadable plans.
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