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How Cheaply Can Good Shelves Be Made?

Bull

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I am putting up OSB or plywood on the back wall of a small, old garage next to my house. The idea is to get as much "stuff" neatly up on the wall as possible. I wont be storing anvils up there, but would like shelves sturdy enough to hold a bit of weight.

I was planning on making the shelves about 18" tall...this sound good to you?

I would like to do this on a super budget, if possible. I don't have much 2x material left, but can buy a little if needed. I have lots and lots of 4x4s and 6x6s, which I don't suppose are going to work too well for shelves. I also have lots of pallets, OSB scraps, 1x boards and various other old pieces of wood strewn about.

I am not very creative, though, nor am I good at engineering or designing things.

I have been and will continue looking at the DIY shelving threads here, but figured a new thread just for me can't hurt.
 
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Brad54

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Decide what you're going to store on them. I like to maximize my shelving units, meaning I put everything into uniform boxes (either office file boxes or clam-shell lidded plastic tote boxes) and then build my shelves accordingly.

For instance, just grabbing numbers here; if you plan on 18 inches, but your boxes are 14 inches tall, that's 4 inches of wasted space per shelf.
If your shelving unit is 6 shelves high, that's 24 inches of wasted space.
Lower each of those shelves just 3 inches, and now you've just "found" 18 inches, or one more shelf on the unit.

In my shop, I've made most of my shelves tall enough for my plastic tote boxes, the bottom shelf being two tote boxes high off the floor (to stack really heavy boxes under the shelves, rather than on them). For my pallet racking I did the same thing, and then I also did a short shelf specifically for intake manifolds, valve covers, exhaust manifolds etc.: short things that won't go in tote boxes, and things I didn't want to stack anything else on.

I have been known to strip everything off a shelf to move the shelf up or down one peg.

When you put your wall up, and the shelves, paint everything gloss white before loading up the shelves. It makes the place brighter, and easier to find stuff on the shelves.

-Brad
 

sargentl

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Do you have a table saw or circular saw to rip the 4x4s and 6x6s into smaller lumber for posts/ a frame?
This video shows a really cost effective way to make some sturdy shelves?
You could do a simple box with osb on top screwed into studs and then some supports on the front of the shelves.
 

c_mccann

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Figure this- 16" shelves- you can get 3 per sheet of ply, 24" shelves- 2 per sheet per ply. 16" can give you 30% more for your buck, can you store what you need on 16"?? CDX ply at 3/4" is about $10 less per sheet than AC (1 side smooth) ply. Chineese Birch ply is about $25 per sheet. With a table saw and a planer, you can clean up the lumber you have and frame to your needs. If you need to really crunch numbers, extra framing (free wood) and 1/2" ply can also work, depending on the weight you are putting on them.. Figure in shelving material, you are $25-30 per 3 16" deep shelves, 8 foot long, plus your labor to frame. If you use the 2x or 4x wood for open sides to the shelves, that eliminates 2 pieces of ply to side them ( if you have solid sides- bookshelf style...)

Figure 2 sheets of ply to go to the ceiling with 6 shelves, 16" deep, 8' long
 

Lkdelta

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Close to Lowes?

The local store did have some 2" X 3" X 8' studs for about $2 ea.
11 of those will frame a 3-shelf unit, 8' wide, 4' high and 16" deep,
with about 12" between shelves, plus 12" below the first shelf,
"stuff sitting on the floor"

each shelf takes 2 "8 footers" for horizontal support, plus 2 pieces cut to 13"
cut 2 of the 8 footers to 4 foot for verticle support
 
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Full Size 66

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The 2x3 stock from lowes works awsome. It does not take up as much space as a 2x4, but still offering good strength. OSB is kinda hack I'd go with plywood unless it is a tear out project (temporary)....
 

ddawg16

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You want at least 16" of clear space.....try to make it big enough to accept the stand storage tub.

Don't listen to the na sayers about OSB...the stuff is fine for shelves.....especially if you paint it.

If you keep the span to about 2, or the width of 2 tubs next to each other, you don't need much front support. Rip about a 1" strip and glue and screw it to the front edge....the back should sit on a 2x4...then run vert posts every couple of feet or so (width of 2 tubs). You will be able to hold a lot of **** that way.
 

Lkdelta

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You want at least 16" of clear space.....try to make it big enough to accept the stand storage tub.

Or for stuff that might not fit in tubs
set all the storage items in 7'6" X 16" rows on the driveway and measure their height

Custom design the distance between shelves for what needs to fit on that shelf
 

countrytech

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+1 on the 2x3 studs at Lowes, 16" deep, and using OSB.

They are cheap but plenty strong enough for canned goods shelving. Don't span over 3' or you will start to see definite sagging in the shelf, canned stuff can get heavy. OSB is what I'm using and it works fine for me.
 

skiingman

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I've built perhaps 1000 feet of shelving in the last two years.

The cheapest, best material in my area for shelving is rough pine straight out of the lumbermill. The last shelving I finished two days ago was built with wood I loaded from the conveyor at the mill directly into the back of the box van.

The latest is about three feet deep, ten feet tall, 14 feet long with nine shelves made from rough cut 1x and uprights from rough 1x4. Cost approximately 225 dollars. Spans between uprights are 4 and two thirds feet. I can climb on it all day long.

OSB is similar in cost for much lower stiffness. Junk for this application in my experience.
 
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egdede

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Figure this- 16" shelves- you can get 3 per sheet of ply, 24" shelves- 2 per sheet per ply. 16" can give you 30% more for your buck...

Except that three 16" shelves have the same square footage as two 24" shelves.
 
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Bull

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Wow, a lot of stuff to think about here! Thanks. Will see about these 2x3s at the local Lowes.

Do you all think it's best to have shelves that have vertical supports? On this back wall, I would like to add shelves that go the whole length of the wall, but which do not have any support "posts" down to the ground. I have seen shelves ion here where the only supports are lags through the ledger into the studs, and then 2xs that go at an angle from the front edge of the shelf to the wall, at a diagonal. Do you know what I am talking about? Is this a light-duty only way t go?

Oh, I should mention: I do not have a planer. I do have a table saw for which I am getting a new blade to be bale to rip 2xs. Is ripping 4x or even 6x a good idea? It's just a basic, older C-man unit.
 

countrytech

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Wow, a lot of stuff to think about here! Thanks. Will see about these 2x3s at the local Lowes.

Do you all think it's best to have shelves that have vertical supports? On this back wall, I would like to add shelves that go the whole length of the wall, but which do not have any support "posts" down to the ground. I have seen shelves ion here where the only supports are lags through the ledger into the studs, and then 2xs that go at an angle from the front edge of the shelf to the wall, at a diagonal. Do you know what I am talking about? Is this a light-duty only way t go?

Oh, I should mention: I do not have a planer. I do have a table saw for which I am getting a new blade to be bale to rip 2xs. Is ripping 4x or even 6x a good idea? It's just a basic, older C-man unit.

I'd be afraid you'll tear up the saw too bad cutting up 4x4s.... just get the 2x3s you'll spend more on electric and a saw than they cost.

I wouldn't trust a wall only mounted shelf for many canned goods.... here again you'll wrap up as much or more cost in hardware, and need to do more complex fabrication, and ultimately end up with an inferior shelf.... just IMO from experience. Nothing beats having a solid post to the ground.
 

skiingman

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You can certainly build a cantilevered set of shelves, complexity depends on the weight they need to support and the depth you need.

I've also built cable stayed shelves supported entirely in tension on threaded rod...you build a thousand feet of shelves and you start fooling around out of boredom.

Depending on cost and load constraints, stamped steel tracks and shelf supports can work well without laborious construction. I've got a couple dozen Super G skis on some of those.
 

Lkdelta

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Do you all think it's best to have shelves that have vertical supports? On this back wall, I would like to add shelves that go the whole length of the wall,

Is ripping 4x or even 6x a good idea? It's just a basic, older C-man unit.

Older saw...7.25" or 10"?

I would put verticle supports in all 4 corners and then bolt or screw the freestanding unit to the wall just to prevent tipping.
You never know what you or someone else might leave on the shelf some day ....(or who might be near the shelf if it fails)..no worries

keep the 6 X 6's for a job that needs them
Ripping 4" is hard work on the saw in lumber that big...if you do it, feed it slow and "completely" check for nail holes before starting..new saw blades aren't new for long, if a nail goes into it.
 
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shannonw

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Here's how i did mine, they go around the entire permitter of the garage. It's piled high full of **** right now just to clear the entire garage floor...this crappy pic is old but there's literally nothing on the garage floor now besides a toolbox and compressor and a few kids bikes.

Cost was 2 bys, few sheets of ply (helps if you make the shelve depth the best depth to make full use of the ply). redhead anchors (for bolting headers into the back block wall). threaded rod, just the rod from hd theaded above thru unistrut spanning 2 joist above to distribute the weight over 2..though i'm pretty sure most of the weight is on the wall not the joist and i made sure to remove everything from the attic (though i have trusses so it's not really useful up there at all anyways). Nails and a few joist hangers.

The advantage to this is no supports under neath blocking useful wall space. I'm sitting here tonight making my plan to line the wall underneath this with home built wall cabinets. Disadvantage is have to have a ladder to reach everything but those are mostly to avoid me going to the attic, it will eventually just have non frequently accessed stuff up there. I can jump up and hang off there without anything even remotely budging.

There's a bit long thread on GJ somewhere where i cribbed the setup from just about. For a neater look you can go back later and even faux frame it.
 

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shannonw

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hrm though with the stock you have 4 and 6 bys i'd probably just consider some type of supported shelf underneath. You can probably pickup a couple of 2 bys. lag or 3" screw into your studs for the back shelf support. come out on both sides with maybe some in the center. Then miter your 4 bys to act as your angled supports. Though 2 bys would certainly work and shouldn't be more than 2 bucks each or so. For shelf material whatever works...if i have a long span and thin ply left over from something i'll use left over 1 bys to add a little extra support, either fill in the shelf box (like in my pic where i used 2 bys) or i'll screw the thin ply into 3 rows of 1 bys (stood on end) to make the shelf. If that makes any sense...
 

shannonw

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Actually here's an idea, if you don't mind taking up floor space you can build something like this with the 4bys and it works great, very adjustable. You'd need a dado blade on your table saw or a cheap router and flush bit will work. Just finished this the other day out of scrap 2bys and some left over pieces of 3/4 ply. Got the idea from here:

http://www.blackanddecker.com/Step-...7ba5Post:3cc5dfc7-272f-41d2-927a-a588355940f3

Just substitute the 2by's with your 4 bys.

Now the shelves are only supported on 4 corners which if using 3/4 ply works fine holds a good bit. But if you needed more you could use your 1 bys to fill in the gap so the entire length is supported.

Make the shelf width and depth to get the most use out of the ply, if you make the measurements right you can have a sheet cut at HD and they'll slide right in. I cut a sheet into 6ths as that's how my space worked out...i wanted them deep to put miter saw,etc stuff up there.

Or really you could skip the dado cuts and just use your 1 bys for the supports, they'd intrude a little on your shelf space but not much and it would support the full shelf sides.
 

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machine_punk

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I've built perhaps 1000 feet of shelving in the last two years.

The latest is about three feet deep, ten feet tall, 14 feet long with nine shelves made from rough cut 1x and uprights from rough 1x4. Cost approximately 225 dollars. Spans between uprights are 4 and two thirds feet. I can climb on it all day long.

Skiingman, do you have any pictures of your style of shelving? It sounds like an interesting idea.

Kev
 
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brucer

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when you build your shelves at least paint the faces of the shelves white.. unpainted shelves **** up the light..
 

Red Leader

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All the suggestions so far are great. I have found that typically the big box stores will cull their lumber every now and then to the point where it is just pennies on the dollar. Sure, the boards are a little warped (usually there are a few straight ones), but if you are cutting it into shorter pieces, it won't matter as much.

If you have a Habitat store nearby, they usually have a few sheets of plywood here and there. I've found them for around $4 or so.

I built these shelves as a part of my '1950s' themed garage:

p6102291.jpg

By daveamy at 2011-06-10
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By daveamy at 2011-06-11
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By daveamy at 2011-06-13
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By daveamy at 2011-06-18
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By daveamy at 2011-07-24

I kinda went overkill:lol_hitti...but my garage is on an ultra cheap budget. These shelves were built out of 2x4s and plywood, nothing else.( okay okay, trim pieces are $2 furring strips). Also, paint helps:)

If I had to come up with a cost, I spent about $30 on 2x4s (full price), $35 for sanded plywood (paid for it, USA made), 10$ on paint, and $10 on screws. There are a lot of other little things that ended up costing me money, but are totally unnecessary. You could cut that down easily to $10 for culled 2x4s, $10-$20 for plywood at a Habitat store, and $5 for screws at same said store (paint too).

Or you could watch C/L like a hawk and ****** up the first 'free' wood postings you see:D

You said you have a tablesaw, older craftsman unit. If it has a good blade on it, it should be fine for ripping stuff down smaller...just watch your hands:)

Spend some good quality time on your design and exactly what you want to do, then go to town. Also craigslist has folks selling leftover 2x4s or plywood pretty frequently.

Good luck and let us know if you need any help!

-Dave
 
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JimDon

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Bull,
If you have a Habitat for Humanity Re-Store near you, check that out. They will have used lumber, hardware, and possibly shelf brackets for at least 1/2 of what a retail store would cost. Google restore for where ever you live. Too bad you're not closer, I'd bring the welder and some angle iron over and fab up some big brackets you could put an anvil on. LOL
Cheers, Jim
 

hdossett

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.... I do have a table saw for which I am getting a new blade to be bale to rip 2xs. Is ripping 4x or even 6x a good idea? It's just a basic, older C-man unit.


I have never had good luck with ripping 2X's, They have a tendency warp!

As for 2x3's, I really like them. Used them for the construction of my workbench/tool storage unit, except for the corner post. Everything was notched, but the corners were double notched, so I used 2x4's. I figure it will hold anything that I could put on it with help of three men.

H
 

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Bull

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I'm digesting what you all have suggested here. My original plan to have shelves secured to the wall only, with no posts going to the floor, is in the ash-bin now thanks to you all. I am gestating some new ideas, though. I'll post some pics of this most unimpressive space soon...really it's more a shed than a garage!
 

SeekMocha

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How about $1.15 per linear foot for 16" deep shelves? I just finished a project similar to this. In my garage I wanted cheap, strong shelving, 16" deep with a minimum of support structure, for storage of heavily loaded flip lid tote boxes. Basically, I drove 20" lengths of rebar into a series of holes drilled in a horizontal line in all studs of the wall where the shelves would go, and laid 7/16" OSB on top of that as shelves.
The details:
I cut 20 foot lengths of 1/2" rebar into 20" lengths (using a SawzAll). Used a laser level to project a horizontal line at shelf height and a Portalign drill guide to make sure I was drilling a 3" deep hole at right angle in center of every stud at the horizontal laser line. I sank each rebar 3" deep into the 2x4 stud. The 1/2" rebar is actually a bit oval shaped, slightly larger than 1/2" in one plane, so I used a belt sander to shape 3" of the end of each rebar into a more circular shape, and I relieved the sharp edges of the cut end of the rod so it would slide into the wood without catching.

I lubricated the insertion end of the rebar with Dove soap to make it slippery and drove it into the holes using a 3lb dead blow plastic hammer. I marked the rod at 3" so I would know when to stop driving it - otherwise you could drive it entirely through the stud and into the adjacent room. I know that by having done it.

Shelving material is 1/2" wafer board (OSB). I cut three 16" wide shelves (8ft long) from each 4x8 sheet of OSB. I laid the OSB on top of the rebar and joined the butting ends of shelves together with nailing tie plates (StrongTie HTP37Z) and 1/2" truss screws (underneath).

In spite of using the PortAlign, some holes were not 90 true and there were minor variations in the true level of the rebar sticking out of the stud. For garage storage, I did not bother to correct the issue. Although I could slip a pipe over the rebar and bend it to be level, the variations were relatively minor so I didn't bother.

Each 16' shelf is now loaded with 12 gallon flip-top tote boxes, each weighing about 40 to 55 pounds, for a total weight of approximately 600lbs per shelf. They are placed on the shelves so the narrow end faces out and they actually hang over the front edge of the shelf a few inches. One wall of my garage has 6 shelves, 16 feet long so the total wall load is 3,600 pounds.

This shelf system cost me about $1.15 per linear foot (in 2013). It's not completely rigid - with the loading described earlier, the front edge of each shelf deflects downward about 1/2". The shelves bounce up and down slightly when putting boxes on them.

A structural engineer would probably not be happy that I drilled six 1/2" holes 14.5" apart in the studs of a support wall, and then loaded one side of that wall with 1.8 tons of weight.

If I was doing this for decorative shelves indoors, I'd probably use plain steel 1/2" rod which is more rigid than the rebar. Rather than trying to drill a hole edgwise into a thick shelving plank, I'd probably rout matching grooves in two boards and then face glue them so the grooves face each other and form holes to be slid over the rods sticking out of the wall. Obviously, price is increasing dramatically for this option.

Several times I had to remove rods that I had already pounded into the stud. I grabbed the rod with a large ViseGrip and pounded the ViseGrip outward with a dead blow hammer. It's imperative that the rod end has been lubricated with something like Dove soap to make it easy to insert and remove.

Obviously, this shelving system is not adjustable - or at any rate, I would not advocate drilling 1/2" holes every two inches up and down studs in a bearing wall in order to provide "adjustable" spacing.

It should be easy and cheap to do this for an 11" shelf, and probably the rebar would be plenty stiff in such a short length and less loading. I would advise using every stud you can locate.
 

bgarrett

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You want cheap? in college we used found cinder blocks and 2X12s :)
no matter what you do, anchor them to the wall
 
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You want cheap?

Take good pallets..longer the better and saw in half down the middle so they still are structurally sound.

Then go buy some concrete blocks..set on end..set the 1/2 pallets on them...stack more blocks...another 1/2 pallet...continue until you are chest to head high.

This setup can hold many hundreds of pounds...and when you tear it down all you have invested is in the blocks that can be used elsewhere.

If you want no expense but your time, you can use pallets for ALL the shelves and use reclaimed nails to put it together. For supports of the shelves you use partial pallets for loadbearing supports.

There is a reason why industry uses pallets for darn near everything.

In keeping shelving cheap, you have to stay away from using panel goods...hard to find used.

With the pallet setups, you can use layers of cardboard to bridge any spans on the pallets for a smooth surface.

Paint? An unneeded expense.
 

RobSmith

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Quote..I am not very creative, though, nor am I good at engineering or designing things.
EVERYONE is not very good at anything at birth.....It's a learning thing. Do a bit of research and Have a Go. I never knew how to machine on the lathe but I have learn't how to do it without a special course or a particular teacher......have a go...I've built a car...so far.
 

5lima30

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Check your local surplus building materials places. I have found "utility grade" plywood and OSB which is not engineer stamped for less than 1/2 the cost at the big box stores. (I wouldn't build a house with it but for shelving it would work fine.)
 

383 240z

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http://woodgears.ca/shelves/garage.html

I built these a few weeks ago. 8' long 4 shelves 2' deep. I glued the whole thing and ran 8" long timber framing screws with 1" heads thru the 2x4 uprights into the studs of the wall. I have it loaded with some pretty heavy totes right now. I grabbed the top shelf and climbed up on the shelves, I'm darn near 300 lbs. and I felt very secure. Keith
 
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Check your local surplus building materials places. I have found "utility grade" plywood and OSB which is not engineer stamped for less than 1/2 the cost at the big box stores. (I wouldn't build a house with it but for shelving it would work fine.)

In my experience, sheet goods are a rare find at a surplus building place.

Because of that, I would plan shelves around not using it.
 

mikec35

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http://woodgears.ca/shelves/garage.html

I built these a few weeks ago. 8' long 4 shelves 2' deep. I glued the whole thing and ran 8" long timber framing screws with 1" heads thru the 2x4 uprights into the studs of the wall. I have it loaded with some pretty heavy totes right now. I grabbed the top shelf and climbed up on the shelves, I'm darn near 300 lbs. and I felt very secure. Keith

Keith, I like the shelves in your link. Do you recommend a veritical every 16" or 32"? I would like to do this style of shelving on (2) 12' sections of wall.
Thanks, Mike
 

crewchief888

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all the shelves in my garage were built using "leftovers" from other projects.

shelf brackets were leftovers & from garage sales, flea mkts, HFH restore.

wife has a habit of wanting shelving, or whatever, and couple years down the road, she changes her mind, plus we were renting, so nothing was permanent, and stayed with us when we moved

i never tossed out anything that she had used, it all ended up stored until we bought this house.

i have a ZERO dollar budget for the garage, nothing new (7 years) has been bought to use in the garage (or reloading room) for furnishing or storage.


:beer:
 

383 240z

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Keith, I like the shelves in your link. Do you recommend a veritical every 16" or 32"? I would like to do this style of shelving on (2) 12' sections of wall.
Thanks, Mike

I used the 24" spacing the previous owner decided was good for the walls he built. I would say depends on what kind of weight your planning on using for shelves, mine are made from 1" thick rough sawn pine. If your storeing books or other heavy items, I'd use one upright every stud. Light stuff like Christmas ornaments every 32" should be fine. Keith
 
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