DIY Network

Urban Conversion (3 of 4): Hidden-Support Shelf System From "Kitchen Renovations" episode DKTN-307

	Host Paul Ryan and our homeowner (Erica) take an old 1920s restaurant kitchen that had been empty for years ...
	and turn it into an eye popper ...
	without losing its sense of history.
	In this third part of "Urban Conversions," free-standing shelves were built.
	The walls were covered in tiles ...
	and the counters and stove hood were installed.

Materials for Building Shelves --

Skins (flat panels same as cabinets)
5/8" plywood
Luan
Angle iron brackets
Paneling or construction adhesive
Caulk gun
Impulse nailer and pin nails
Trowel
Cordless drill
T-bolts (we used 5/16")
T-nuts
Hammer
Grinder
Clamps
Sharp hardened alloy bit
Cardboard

Materials for Tiling --

Dust mask
Limestone/glass tile
Cement backer board
Utility knife
Construction adhesive
Cement board screws
Screw gun
Thin set mortar
Water
Bucket
Backerboard
Drill
Jigsaw
Paddle mixer
1/4" V-notch trowel
Sponge
Wet saw
High quality grout float
Fortified unsanded polymer grout
Dry trowel
Straight edge
Sealer

Materials for Scribing Sink --

Japanese pull saw
Masking tape
Pencil
Utility knife
Chisel
Level

Materials for Installing Countertop:

Wood cleats
Skins
Caulk gun
100-percent silicone

Materials for Installing Hood:

Range hood and parts
Drywall jab saw
Aviation snips
Tape measure
Gloves
Safety glasses
Drill

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Building the Hidden-Support Shelf System

1. Place angle brackets on the wall where you want the free standing shelves to go.

2. To make the shelf, you take a skin and make the bottom of the shelf, a piece of 5/8" plywood is added, then a spacer made out of luan that is the same thickness as the angle bracket, and a top skin goes on top.

   Note: Angle iron brackets are made of steel that is 3/16" thick.

3. Glue 5/8" plywood to the bottom skin, and then glue the skin trim to the front and sides of shelf to cover the wood sandwich core. Use pin nails to help hold the trim in place until the glue dries (figure A).

4. Use a bead of construction adhesive glue on top of the plywood and spread with a trowel (figure B), this is the base for the next layer, which is the Luan.

   Note: You can use paneling or construction adhesive.

5. Put Luan on after the glue has been spread and hold with pin nails. The Luan is approximately half the width of the shelf -- allowing room to slide onto the angle bracket (figure C).

6. Repeat the application of the construction adhesive to this layer then put top skin in place and nail. This is actually the bottom of the shelf and won't be seen, so regular nails can be used securing the whole unit.

7. After the planks are glued, drill pilot holes near the end of the board for the T-Bolts that will line up with holes that will be drilled into the angle iron.

   Tip: You can assemble shelves while the glue continues to dry.

8. Using a slightly larger drill, countersink the hole to receive the head of the T-Bolt, repeat on the other side of the shelf for the T-Nut. The T-Nut has sharp edges that can be nailed into the shelf to stay.

9. Using a slightly larger drill, countersink the hole to receive the head of the T-Bolt, repeat on the other side of the shelf for the T-Nut. The T-Nut has sharp points that are tapped into the wood (figure D) and they stay there for good.

10. Once the shelf is glued together, use clamps to hold in place until the glue dries.

11. Slide the shelf onto the angle bracket and use the pilot holes to drill through the angle iron where T-Bolts will go (figure E), clamping the shelf to the angle iron.

    Note: Use a sharp hardened alloy bit when drilling through steel.

12. Grind off the end of the T-Bolts so they do not stick above the shelf. Be sure to use cardboard to protect the wood. (figure F).

In the next segment cement backerboard is put up to prep the wall for the limestone tiles, which Ryan and our homeowner start to lay.

RESOURCES :

Veneer for Shelving
Brand name: IKEA
Color: Dark-stained eucalyptus veneer
IKEA
Website: www.ikea.com

100-percent Recycled Glass Tile
Brand name: Bedrock Blazestone
Model: Classic Series 2x4
Color: Cloud White, Mineral Water, Celery
Where available: Visit the Bedrock Industries website, link below.
Bedrock Industries
1401 W. Garfield St.
Seattle, WA 98119
Toll-free Phone: 877-283-7625
Website: www.bedrockindustries.com

Enameled Lavastone Countertops
Brand name: Pryolave
Color: V240
Where available: Visit the Pyrolave website, link below.
Pyrolave
1817 Kenwyck Manor Way
Raleigh, NC 27623
Phone: 919-788-8953
Website: www.pyrolave.com

Kitchen Sink
Brand name: Julien
Model #: 0150
Color: Stainless Steel
Where available: Visit the Julien, Inc. website, link below.
Julien, Inc.
Website: www.julien.ca

Faucet
Brand name: Helix Pontiac
Model #: HX1170
Color: Matted Stainless Steel
Where available: Visit the Lefroy Brooks website, link below.
Lefroy Brooks
Website: www.lefroybrooks.com

Range Hood and Flue Extension
Brand name: Sirius
Model # for hood: 120 x 48
Model # for flue extension: SU1 x S430L 14"
Color for both: Brushed Stainless Steel
Where available: Visit the Sirius website, link below.
Sirius Range Hoods
Website: www.siriushoods.com

GUESTS :

Shane Kretsinger
Vice President, Operations
Autumn River
We apologize no contact information is available.