Welded metal shelf brackets for floating shelves
The combination of black painted iron and solid oak wood is not only suitable for the tables or for the office desks, but also for the floating shelves installed by using welded metal shelf brackets.
We have build oak countertops and table tops over time and we wrote about them in various articles (other articles will come sooner). So, we will not insist much on the shelf itself. All we can say is that this floating shelf was made out of 2 cm thickness continuous oak wood planks by using our simple clamping system which tightens and flattens the panel in the same time. The shelf is 100 cm long and 31 cm deep and it was protected with scratch-resistant polyurethane primer and varnish. The edges have been beveled so that there is no sharp edge.
We chose a very simple model for the metal brackets. We used 2 cm square bar.
We cut 3 pieces from the metal bar for each small bracket to form a rectangular triangle with two sides of 30 cm and 20 cm. The other side, the hypotenuse had about 36 cm. We chose 30 cm for one side of the brackets because on this side will be fixed the oak floating shelf of 31 cm deep. In this way the shelf can be supported on the almost its entire width.
Another important aspect that we took into account is that we did not want that the screws to be visible (those screws with which the brackets will be fixed on the wall and those screws with which the shelf will be fixed on the brackets). Aesthetically, it is impossible not to see the heads of the screws, even if I wanted to use black screws. If I couldn’t find any black screws I was planing to paint them with the same black paint. Besides all these, we definitely would not have had space for the cordless screwdriver. The space between the sides of the brackets is very small, so they should be screwed manually and the tightening would not be perfect, but safe.
I drilled holes with an 8 mm drill bit: two on each side of 30 cm and one on each side of 20 cm. Then I made one 2 cm long channel, starting from each hole. These cutouts will help to fix the brackets on the wall and to fix the floating shelf on the brackets.
We also cut one of the corners of the brackets (the visible one), so that we can use metal caps, cut from the same metal bar. After we welded all the pieces, we sanded the welds very well and rounded the edges slightly using the angle grinder. You can see how our metal brackets look like in the pictures below. There are small holes left after the welding and sanding the iron.
We used a two-component polyester kit (or car body filler, putty), extremely useful for filling the little holes left after welding . First of all, this type of filler is very resistant and secondly it dries very quickly. The only disadvantage is that it hardens rather quickly and should be mixed in as small quantity as possible so that you do not throw away too much at each use.
We apply the filler with a spatula. It is preferable to apply a thicker layer to ensure that the holes have been completely covered to save more time. Otherwise, it is necessary to sand the filler and to apply another layer and then it is necessary another sanding.
This kind of filler can be very easily sanded even with 120 grit sandpaper.
We sanded very well the dry car body filler using the multi tool with 120 grit sandpaper on the flat surfaces. For the interior corners of the welded metal shelf brackets we sanded the excess putty, manually.
We applied the primer for metallic surfaces. After the primer was dried we sanded it with 320 grit sandpaper to make the surface as smooth as possible.
Then, we applied a layer of special black paint for metallic surfaces.
Here are the two welded metal shelf brackets made for the 2 cm thickness oak wood floating shelf:
We also received from our customer the pictures with the floating shelf and the two decorative metal brackets: