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Rustic Wall Shelf

author-gravatar Sean Dec 11, 2016

This rustic wall shelf was inspired by another one of my projects, the rustic trunk with a hidden compartment. I really liked the look of the pallet wood with the finish on it and wanted to build another piece for my house. This whole project was made out of 1x4 pallet wood that I picked up from a local farmer for 30 cents a board. I bought a few extra pieces to make sure I could pick the best looking boards for the shelf.

The overall length is 29 inches and the shelf is 8 inches deep and 11 inches tall. The joinery for this shelf is all done with a couple of doweling jigs. It's an easy way to get strong joints fast. For the finish, again I went with the same finish I used on the trunk which is a semi-gloss spar urethane from Minwax. Check out the build video below as well as the accompanying photos.


Products used(affiliate links)
Milescraft doweling jig: http://amzn.to/2gpMAtr
Traditional doweling jig: http://amzn.to/2gB6m8A
Dowel alignment pins: http://amzn.to/2hsVXxh
1/4" dowels: http://amzn.to/2gPwFp6
Minwax spar urethan semi gloss: http://amzn.to/2gBbfOV
Titebond hide glue: http://amzn.to/2hjJGrF
F-Clamps: http://amzn.to/2gpYTGh
Quick Clamps: http://amzn.to/2ht6GrI

Photo of Rustic Wall Shelf
Photo of Rustic Wall Shelf
Photo of Rustic Wall Shelf
Photo of Rustic Wall Shelf

These are the 1x4 pallet boards that I picked up from a local farmer for 30 cents each. They are roughly 3/4" thick but some boards where a little thinner so I had to be a little picky when making the panels.

Photo of Rustic Wall Shelf

This is a picture of my trunk that I made out of the same lumber which inspired me to build the shelf.

Photo of Rustic Wall Shelf

Each of the shelf panels (top, bottom and sides) are all 8" wide and required 3 boards glued together to get the width needed. When picking the boards to make the panel, choose the flattest boards with the straightest edges. 

Photo of Rustic Wall Shelf

With the ends flush, I strike a line at 26" with my combination square.

Photo of Rustic Wall Shelf

I use a stop block jig at my miter saw to ensure that I will get the same length when I cut the boards for the top and bottom panels.

Photo of Rustic Wall Shelf

This is how I use the stop block. I push the board up against it and cut.

Photo of Rustic Wall Shelf

For the side panels I move the stop block in for 10" cuts.

Photo of Rustic Wall Shelf

This is the first doweling jig that I used in this project. It's really easy to use, mark a reference line across 2 boards and then line that line up with the white line on the doweling jig and drill.

Photo of Rustic Wall Shelf
Photo of Rustic Wall Shelf

I use a stop collar on my drill bit to make sure I don't drill too deep. The top/bottom panels get 3 dowels in each board and the side panels get 2. This is better explained in the video.

Photo of Rustic Wall Shelf

With the dowels drilled I put glue on the edges and in the dowel holes and clamp them up.

Photo of Rustic Wall Shelf

For the 90 degree joints I switch doweling jigs. I wanted to mention that you don't need 2 doweling jigs. I just used the other jig because it's faster for edge joining boards to make panels but when it comes to drilling holes on the faces of boards, it can't, so I switch to the milescraft doweling jig(http://amzn.to/2gpMAtr).

Photo of Rustic Wall Shelf

I use the self centering pins on the doweling jig to drill holes on the edge of the top/bottom panels.

Photo of Rustic Wall Shelf

I then place the jig over one of the dowels and slide the fence forward until it touches the board.

Photo of Rustic Wall Shelf

With the side board laying under the top panel, I drill the holes for the dowels on the face of the board, referencing the dowel holes in the bottom panel.

Photo of Rustic Wall Shelf

All 4 corners have dowels now.

Photo of Rustic Wall Shelf

Next I build the little "L" shaped bracket that will house the drawer. I cut the pieces to size at the table saw.

Photo of Rustic Wall Shelf

And just like before, I use the doweling jig to first drill holes in the edge of the smaller board and then reference those dowels for drilling on the larger bracket piece.

Photo of Rustic Wall Shelf

Time to glue up the bracket. I used titebond hide glue on the whole project.

Photo of Rustic Wall Shelf

And finally, to mount this bracket to the shelf, I drill 2 dowel holes on the bottom.

Photo of Rustic Wall Shelf

And the top.

Photo of Rustic Wall Shelf

To determine where I need to drill holes in the shelf panels, I use these little metal dowel alignment pins that slide into the dowel hole and have a centered point on the other end.

Photo of Rustic Wall Shelf

I put the bracket where I want it to go and give it a good tap.

Photo of Rustic Wall Shelf

These are the indentations that the alignment pins leave.

Photo of Rustic Wall Shelf

With the depth collar adjusted on my drill bit, I drill the holes for the dowels in the shelf.

Photo of Rustic Wall Shelf

Before gluing the shelf up, I sand everything with 180 grit sandpaper. This removes any lose dirt or grime, but leaves the rustic appearance.

Photo of Rustic Wall Shelf

The glue up on this case will need to be done in a certain order. I started by gluing the dowels in the ends of the top/bottom panels, then I glued on the right wall, then the L shaped bracket, top was next and then the left wall.

Photo of Rustic Wall Shelf

Threw a few clamps on to make sure everything came together.

Photo of Rustic Wall Shelf

While the glue was drying on the shelf, I cut 3 boards to length at the table saw for the top.

Photo of Rustic Wall Shelf

I didn't use dowels to reinforce the top because i'm going to glue the top to the shelf which doesn't need any support.

Photo of Rustic Wall Shelf

While everything was drying, I went ahead and cut my french cleat. I tilted my table saw blade to 45 degrees and rip a board in half.

Photo of Rustic Wall Shelf

To attach the cleat to the shelf, I first glued it in place and then used a few screws to reinforce it. Don't worry about the screws showing because the top gets glued on the shelf sub top which will hide the screw holes.

Photo of Rustic Wall Shelf

With everything dried, I go ahead and glue the top on just using the same hide glue.

Photo of Rustic Wall Shelf

With the top evenly spaced, I put a few clamps on to keep it in place until the glue dries.

Photo of Rustic Wall Shelf

I move on to the drawer and cut the boards to width at the table saw.

Photo of Rustic Wall Shelf

The drawer front has a groove on the ends that the drawer sides will be glued to, so to cut that, I use my miter gauge at the table saw and slowly remove the waste with multiple passes.

Photo of Rustic Wall Shelf

To cut the groove in the bottom of the drawer parts for the drawer bottom, I set my table saw fence to 1/4" and raise the saw blade to 1/8" and make a pass. I then move my fence over 1/8" and make another pass. This gave me a 1/4" groove 1/8" deep for the drawer bottom. Next I cut the drawer bottom to size at the table saw.

Photo of Rustic Wall Shelf

I apply glue to the grooves for the drawer sides

Photo of Rustic Wall Shelf

And clamp them up. When the glue dried, I cut the drawer back panel and glued it between the left and right drawer sides.

Photo of Rustic Wall Shelf

To reinforce the drawer joinery, I drilled an 1/8" hole and glued in brass pins. This not only makes it stronger, but the brass looks great with the cherry lumber.

Photo of Rustic Wall Shelf

I used a semi-gloss spar urethane from minwax on this project.

Photo of Rustic Wall Shelf

I brushed on 2 coats, without sanding in between.

Photo of Rustic Wall Shelf

And finally, I installed a brass knob on the drawer front.

Photo of Rustic Wall Shelf

To hang the shelf, I hung the french cleat on the wall, making sure to drill in to the studs.

Photo of Rustic Wall Shelf

And then slid the shelf over the french cleat. This is a great way to hang things like this. Thanks for checking my shelf out, I really appreciate it! Check out my YouTube channel where I post build videos like this.

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