Building shelf above workbench

[Mmfh]

Hey there,

I'm building a heavy duty shelf above my cylinder head assembly bench, I wan't to "bag and tag" heads when they are finished and line them up on this shelf.

I figure this shelf should be able to easily hold 1000 lbs, 1,500 lbs would be great. I'm doing a basic 2 x 4 box frame with cross supports every foot or so and then sheeting it with 3/4" plywood. Problem is supporting this shelf and still have it look nice.

I'm going to trim out this shelf on the front with some stainless or something similar, want it to look nice and clean. Don't want to have weight supports from the shelf going down to the bench top, really don't like the looks of the triangular supports from the bottom and also don't really like the looks of that type of support on the top either.

My wife had the idea of using cables from the shelf going up to a couple of ceiling joists. I have 2 x 12's going across the ceiling, I would be attaching the cable about 2' out from the wall.

Anybody done anything similar to this, or have any idea's or pictures of their setup?

Sorry I don't have any pics, haven't got the camera thing working yet.

Thanks for any idea's you might have!

Mm

 

[Steevo]

A couple of questions for clarification:

How long will this shelf be?
How deep?
Are the 2x12's exposed above?
Do the 2x12's run parallel to the bench/wall, or perpendicular to it?
Is the bench wall made of 2x4's or 2x6's, and how are they spaced?

 

[daveroy]

If you are going to put that kind of weight on it right over the bench, I would want some kind of lip, maybe 1/4", to make sure stuff doesn't roll off and hit you or ruin something on the bench.

Other than that... I got nothin. (cool Idea though!)

 

[Mmfh]

A couple of questions for clarification:

How long will this shelf be?
How deep?
Are the 2x12's exposed above?
Do the 2x12's run parallel to the bench/wall, or perpendicular to it?
Is the bench wall made of 2x4's or 2x6's, and how are they spaced?

The shelf will be the same length as the bench, 10' and 18" deep. The 2 x 12's are exposed and they run perpendicular to the bench, so I would be attaching to two different 2 x 12's out about 18" from the wall.

The wall behind the bench is 2 x 4, 16" OC.

Thanks!

Mm

 

[On1Wheel]

How about, instead of cable, you run pipe down from the ceiling and through the shelf. With the trim on there, I think that might look really cool. Pipe would be a lot stronger, too, I'd think. Kind of like these:

 

[Brad54]

Can you weld?
I would go with industrial pallet racking. If you can't find any that's 18-inches deep, you'll have to cut the diagonals on the uprights and narrow them, weld back together, paint and install.

By the time you get done buying the materials to make your own, I think you can get the pallet racking as cheap or cheaper.

-Brad

 

[Eagle Point]

Mount a 4x4 post crossways between the 2x12's and run 1/2" all -thread rod from the shelf up through the 4x4 above. I just built a loft in my garage, 24' long x 4' deep and supported it this way every 6' and it is very secure. I had access to the crawl area above and ran the all-thread through the ceiling and ran a 4x4 across the 2 trusses for each rod in the crawl area. Put a large metal washer or plate and a nut and you should be good. I covered the all-thread with foam that you insulate plumbing pipes with and it looks really clean.

 

[Mmfh]

I like that pipe idea, it would be strong and also have that industrial clean look I'm after.

I will also check into some pallet racking to see what it looks like. If its what I think it is, I don't think it will have that clean look I'm after, but I could be wrong.

Different idea's are Great, Please keep them coming!

Thanks,

Mm

 

[Mmfh]

Mount a 4x4 post crossways between the 2x12's and run 1/2" all -thread rod from the shelf up through the 4x4 above. I just built a loft in my garage, 24' long x 4' deep and supported it this way every 6' and it is very secure. I had access to the crawl area above and ran the all-thread through the ceiling and ran a 4x4 across the 2 trusses for each rod in the crawl area. Put a large metal washer or plate and a nut and you should be good. I covered the all-thread with foam that you insulate plumbing pipes with and it looks really clean.

That's another good idea! I'm thinking maybe using the pipe idea and going up to a 4 x 4 with the pipe like you did with the all thread?

 

[Steevo]

Here are a couple of ideas. I have used them both with success before.
One shows how to use a u-shaped strap to provide a hanger for a cable or chain support, and the other uses flat steel T's to bolt through studs and your shelf supports to provide a free-hanging shelf that will hold a lot of weight if every stud is used and the brackets are sandwiched on both sides.

 

[Mmfh]

Here are a couple of ideas. I have used them both with success before.
One shows how to use a u-shaped strap to provide a hanger for a cable or chain support, and the other uses flat steel T's to bolt through studs and your shelf supports to provide a free-hanging shelf that will hold a lot of weight if every stud is used and the brackets are sandwiched on both sides.

I like both of those idea's, I was wondering if I did use cables how I would get the tension the same on both cables, with a eyelet bracket like that I could use the eyelet up/down adjustment to tighten the cable.

Also really like the no supports idea! I hadn't even thought of that because of the weight involved but with the right brackets it should work.

My gears are really turning now, I'm going to go do what I do best, stand around and stare at a project until the solution jumps out at me. I'm liking those brackets allowing me to not have supports getting in my way.

Thanks very much!

Mm

 

[jonese]

I immediately thought of using chains to support the shelf. Even though there's a little more work involved, I like the look of the pipe better. The pipes should be strong enough to support the weight too.

 

[PCO6]

They're a little hard to see in the photo below but I welded up 2 braces for a shelf above my main bench. The shelf itself made of 2"x6" lumber and can hold a LOT of weight.

The braces are on either side of the plastic bin rack on the right side of the bench. They are made of 1/8" wall 1"x1" square tubing. They are basically a 30"x30" "L" with a brace welded in at 45 degrees. They are bolted to a concrete wall with tapcons and the 2 by lumber sits on top bolted down with simple wood screws.

I think you want your shelf to be lower for cylinder heads but simple braces like these should work.

 

[Mike F]

I have that exact type of shelving in my garage. I used heavy duty angle brackets, which if I recall correctly are from Home Depot. I used 3 of them on a shelf which is 8 ft long. I have over 1000 lbs of solid oak on it without any problem. I have tugged on the shelf pretty hard too- just to be sure it would hold. The back of the shelf is lagged into the wall studs, as is the one side of the shelf that is against the side wall. Here is a link to those brackets from Rockler, but you can find them many places. http://www.rockler.com/product.cfm?page=126

 

[Falconman]

All I can say is dont use screws in building it. Use bolts with washers and nuts.You are talking weight you know.

 

[Mmfh]

Well the shelf is built and up, attached on the back wall and also on the left side of the shelf as this is in a corner.

I believe I'm going to go with the pipe or cable idea, not sure yet which way but most likely one of the two. I like the pipe and flange idea and my wife likes the cables. Yea my wife is in on this too. When she is involved it makes buying things easier, and I enjoy her company out there trying to help me.

Thanks guys for your idea's!

Mm

 

[cadunkle]

I like the pipe setup. Should be strong and looks clean. As Falconman said, use bolts. I'd probably make a plate for the underside through bolts that spreads the load on your supports/framing and not just screwed right into the surface, given the weight we're talking about.

 

[cgv69]

I would look into a torsion box type shelf. Basically the design concept used to build aircraft wings. The only problem is most torsion box shelves are designed for much less weight. I've seen some made if 3'4" plywood webbing and 1/4 ply for the "skins" that could easily support a full grown man. I'm sure one could be built beefy enough to support 1500lbs but I can't point you to a source or guide that can tell you exactly what materials and dimensions will be needed to support that kind of weight? Some trial and error will probably be needed.

 

[On1Wheel]

Well the shelf is built and up, attached on the back wall and also on the left side of the shelf as this is in a corner.

I believe I'm going to go with the pipe or cable idea, not sure yet which way but most likely one of the two. I like the pipe and flange idea and my wife likes the cables. Yea my wife is in on this too. When she is involved it makes buying things easier, and I enjoy her company out there trying to help me.

Thanks guys for your idea's!

Mm

She was sitting there as you wrote that, wasn't she?

 

[kbs2244]

Before you get too far into this project I would think about how you are going to get the heads up and down from the shelf.
What do they weigh?
How clumsy are they to handel?
How much are you going to have to reach out over the bench?
(I guess I see back injury in the future.)
I would make a mock up of some kind and try it out for "fit."

 

[Jack Olsen]

That was my thought. The heads for my Porsche engine are heavy suckers. I'd want to store them down low.

 

[stinkity stoink]

I built mine out of angle iron. Used 3/4 plywood as the base. I used eye bolts in the cieling with cables. It's pretty strong ,but I don't know about 1000 lbs. I am sure it could be tweaked a little though.

here is a pic. Hopefully you can see the cables

 

[stinkity stoink]

one more .
sorry found it after the post

 

[NUTTSGT]

Before you get too far into this project I would think about how you are going to get the heads up and down from the shelf.
What do they weigh?
How clumsy are they to handel?
How much are you going to have to reach out over the bench?
(I guess I see back injury in the future.)
I would make a mock up of some kind and try it out for "fit."

That thought had crossed my mind too, so much that I reread the original post twice.

Sorry, but any way I see this being built, especially over your workbench, I see bad things happening.

Good luck on your build.

 

[buzz4041]

I have used large turnbuckles for the hangers of heavy duty shelves in the past.

 

[Mmfh]

A couple of you guys have brought up the fact about weight and lifting it over the bench and up to the shelf, I don't think it will be a problem. This shelf I built is exactly 2' above the bench top, and comes out 18" from the wall.

I've had a few back surgeries and although heads are heavy I know I can get them up there. When I was a kid starting out in the business I worked for a guy who had the entire back wall of the shop with finished heads on them, very convenient and easy to see what you have without moving anything. Besides I'm 6'2" and 250lbs and I've been muscling these things around all my life. Its all in how you handle the weight.

I'm happy with it so far, in a small shop you have to get creative about how you store things, unfortunately you sell a "LOT" more cylinder heads if they are done and ready to go when someone calls. Sell them the heads on the shelf, rebuild there cores and back up on the shelf.

So far so good! Thanks guys for all your help

Mm

 

[Mmfh]

I have used large turnbuckles for the hangers of heavy duty shelves in the past.

I figured I would use turnbuckels if I end up going with cables.

 

[Mmfh]

That was my thought. The heads for my Porsche engine are heavy suckers. I'd want to store them down low.

Hey Jack, those 911 heads are fairly lite compared to a set of big block Chev or Ford. Always getting calls for those.

I'll mostly be doing aluminum hopefully, everything is going that way and I want to deal with the hot rod guys who have the money for the cool stuff!

 

[Mmfh]

She was sitting there as you wrote that, wasn't she?

No of coarse not! But she might read it later