How To Build Bar Shelves

Stain all wood

Plan to stain the day before you build your bar shelves to allow it to dry.

Use 220-grit sandpaper to lightly sand the splinters and raised grain before staining the wood for shelves and trim pieces. Let them dry overnight, and then cut your pieces.
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Nail the face trim

Starting with the face trim (B), use 1-1/2-inch, 18ga. brad nails and wood glue to attach the trim flush to the top edge of your shelf (A). Use a loose side trim piece (C) to ensure the mitered ends of the face trim (B) align with the shelf (A) corners.

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Nail the side trim

Secure the side trim (C) pieces on either side flush to the top of the shelf (A) with the brad nailer and wood glue. Make sure the miters are tight before nailing.
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Fill, stain, and seal

Fill all nail holes on the bar shelves with wood filler and allow it to dry. Use a wet rag to rub the filled holes flush with the wood. Touch up the stain to hide the filler. Allow the stain to dry sufficiently before applying polyurethane.

Once the stain is completely dry, brush on two coats of oil-based polyurethane. Allow each coat to dry, and lightly sand back the raised grain with 320 grit sandpaper between coats.
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Install the shelf support brackets

The easiest and strongest way to secure a shelf on a wall is to use pre-manufactured shelf support brackets screwed into the wall studs. Locate studs beneath the drywall with a stud finder, and use two-inch screws to drill the shelf support brackets into the studs. Use painter’s tape and a level to create a level line to ensure the shelf is level. A small torpedo level is also handy to ensure the shelf support brackets themselves are plumb.

If the ideal placement of the support bracket lands on hollow drywall, first install a drywall anchor for the appropriate weight of the shelf plus what it will have on it, and then secure the brackets to the wall with the included screw.

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Install the shelves

Install the completed wood bar shelves onto the shelf support brackets attached to the wall. Be sure to use screws that aren’t too long and will poke through or dimple the top of your shelves (A).
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Install the tipping rail

Install a tipping rail along the edge of your bar shelves. You can find these at a few places online, but I liked the look and ease of installation of the Chunky Modern Brass Gallery Shelf Rails from Pepe & Carols, so I went with them.

Place the screws for stand-offs 1-1/8-inches from the front edge of the face trim (B) to ensure your screws have enough wood to bite into for a solid installation.

Follow the manufacturer’s instructions for the tipping rail and install it according to the spacing of the tipping rail purchased. Screws for the stand-offs should be drilled and installed up through the bottom of the shelf (A) so they poke out through the top surface. Make sure your screw holes are drilled as straight as possible so your stand-offs end up plumb.

If you need to adjust the length of your tipping rail, use a metal hacksaw to cut back the excess bar and sand the metal burr from the cut with a 100-or 120-grit sandpaper to make the rod smooth on the ends.

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FAQ

When do I choose water-based vs. oil-based sealers?

Most carpenters will tell you an oil-based finish has better durability. If it is a high moisture area, opt for an oil-based finish. If you don’t want the color of your wood to change or yellow, use a water-based sealer or polyurethane. Oil-based finishes tend to yellow as they age. Water-based sealer will retain the original color of your stain for a longer period. Not all sealers will fully protect from sun damage or fading.

Can I use more than one color stain to reach a desired color?

Yes! When trying to match another species of wood or an older piece of furniture, you may find the need to mix more than one stain color to achieve the desired match. Here are a few rules to make the multi-color staining process successful.

• Never mix oil-based stains with water-based stains. Stick with one or the other for all multi-stain color combinations.
• Apply the layers of stain one at a time and be specific with applying it in the same color order and how much time is allowed between different stain colors. With any large staining project, you will have to repeat the stain process over and over on different pieces of wood – which means to ensure an even coat, you have to be consistent in how you apply it. Same color order with the stains and same amount of time allowed to saturate into the wood.
• Always test the different stain colors together before you apply it to your final product.
• When using multiple stain colors to create a custom color, be sure to apply them all in the same order. Changing the order may change the final color blend.
• Stick to the same wood species for the whole project because different wood species absorb stains differently, thus giving you a different result.
• If you can repeat your process, it is a success. If you can’t repeat your process, it is a fail.