Barn wood has great shelf life

Hands-on time: 1 hour per box shelf.
Total time: Add stain and glaze drying time.
Skill: Moderate, requires basic tool skills.
Cost estimate: Depends on the price of wood (about $15 to build three box shelves).

Materials & Tools

• Barn wood (available at salvage centres and flea or country markets). Large shelf shown is two 5 x 35 x 1" (12 x 89 x 2.5 cm) thick pieces (top and bottom) and two 5 x 7 x 1" (12 x 18 x 2.5 cm) pieces (sides). Adjust the dimensions to suit your purpose.
• Measuring tape
• Pencil
• Hand saw, mitre saw or, if available, a table saw
• Mitre box or carpenter's square
• Sanding block, and a tack cloth
• Carpenter wood glue
• 1-inch (2.5 cm) finishing nails, and a hammer
• Minwax driftwood stain and a foam brush (optional)
• Grey acrylic paint and glaze, paintbrush (optional)
• Lint free cloth
• Varnish
• Hooks
• Level
• Drywall plugs, flat head screws, and a screw driver (to mount shelves onto the wall)
• Vice or clamps (optional)

With salvaged barn wood you can make weathered shadowbox shelves that compliment Cape Cod, country and even minimalist decor styles. Old fences or driftwood pieces can also be used.

Decide how many shelves you want and the dimensions for each. When you select the barn wood, make sure it is dry and that the pieces will provide you with enough wood for your project. It is important to make sure the wood is bug free and not rotting or soft. To remove any dirt or unwanted particles, sand the surface lightly.

Start by cutting the needed lengths for each side of your shelves. Measure the wood, then, using a table saw or hand saw, cut the larger lengths. For the smaller pieces use a mitre saw or hand saw and a mitre box. A mitre box is an open-ended box that has slots in the sides, which you use as a guide to make a straight cut. If you don't have a mitre box, then use the carpenter's square to mark lines across the face and around the sides of the wood. Then cut along these lines. You will use the same technique to assemble any size shelf. On a flat surface, lay the two larger pieces horizontally and parallel to each other. Place the two smaller pieces vertically to the left and right of the larger ones. Make sure that the larger pieces cover the 1" (2.5 cm) top and bottom edges of the smaller pieces. This means the smaller pieces will be between the larger ones. Ensure the outside surface of the smaller pieces sit flush with the top and bottom edges of the larger pieces. Where the four pieces join to make a box, apply wood glue and spread it out with your finger. Hammer the nails into the wood to join the pieces together.

For the finish, sand lightly around the edges and the sides, then wipe with a tack cloth. Apply your choice of stain colour and let dry. I used a driftwood colour to keep an authentic look. Once dry, I applied a grey glaze mix, using a brittle paintbrush, making sure to penetrate the mix into grooves and dents. Once applied, wipe it off with a clean cloth. This extra step gives the shelves a rustic look. Apply varnish and let it dry overnight.

For the installation, put two hooks at the back of the sidepieces making sure they are an inch (2.5 cm) from the top. Position a shelf on the wall; use a level to make sure it is horizontal. Mark the position on the wall with chalk or pencil. Drill holes in the walls or make them with a small, square-end screwdriver. Place plastic plugs in the holes and screw in the screws. Slide the unit into position on the wall. Display such treasures as rocks, frames, seashells or anything else to suit your home or cottage.

Tips

• You can leave the barn wood in its natural state. Lightly oil it to protect the wood. For a modern look use a resin or diamond finish over a dark stain.

Variations

• Smaller pieces can be transformed into picture frames, serving trays or bat houses, larger pieces into rustic furniture, coat racks, end tables and footstools. Protect outdoor furniture with a water sealer.