Tap Handle Display Shelf (ep13)

We were asked to create 6 custom tap handle shelves for a client that held 10 handles each for their collection. The client was thrilled and we liked them so much we created 2 for Deacon Taproom too!

Materials: 

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Step 1:

Cut your 1″ x 6″ x 8′ select pine boards down to shelf width of 41″

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Step 2: 

Rip each 41″ shelf top to final width of 4″. Save the cut-off as it will produce the shelf support and bolt rails.

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Step 3: 

Take the shelf cut-off and on the table saw rip 2 41″ boards to 1″ in width for the back shelf support and bolt rail.

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Step 4: 

At the drill press, countersink a 1/2″ hole (correction from video) 4″ from the end of the board and every 4″ thereafter deep enough to allow for the 3/8″ hex bolt head to be completely under the surface.

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Step 5: 

Next, change out the forsner bit for a 3/8″ spiral bit and drill the the center of each countersink thru the board to allow for the 3/8″ bolt to come thru 1/4-3/8″ proud of the other side.

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Step 6: 

With the remaining 1″ x 6″ select pine, draw a shelf support bracket that you like. Remember to leave a cutout area for the back shelf support.

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Step 7: 

At the bandsaw, cut out the shelf support bracket.

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Step 8: 

Clean up the bandsaw cut edges at the belt sander and oscillating spindle sander.

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Step 9: 

Back at the table saw, cut out the relief for the back shelf support rail.

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Step 10: 

Now time for some assembly. Attach the back shelf support rail with glue and 18-gauge nails.

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Step 11: 

Optional step; using a router, apply a round over or ogee detail on the left, right, and front sides of the shelf. Do not apply these details to the back of the shelf as it will not sit flush to the mounting surface.


Step 12: 

On each bolt rail, cut off 1″ from each end of the rail. This will allow the bolt rail to sit in the middle of the 4″ shelf with a 1″ reveal on either end. This makes the shelf more pleasing to the eye but is not necessary based on your overall design.

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Step 13: 

On the bolt rail, insert the 3/8″ hex holts into the holes from the bottom side of the rail. The bolts should friction fit into the countersinks and sit all the way down into the holes. No epoxy or glue is needed to hold these but can be used if you so choose to.


Step 14:

Glue and nail the bolt rail to the 4″ shelf directly in the middle of the shelf making sure to leave the 1″ reveal on each end of the bolt rail.

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Step 15: 

Attach the shelf support brackets to the underside of the shelf with glue and nails. These are not going to be physically supporting any weight and are there for aesthetics and to ensure the the shelf doesn’t lean too far forward with any top heavy handles on them.


Step 16: 

Do any last finish sanding and material prep before staining. Then proceed to staining the wood in any color you decide and let dry.

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Step 17: 

Apply your finishing coats to the piece with a light sanding in between. Once dry, install using screws thru the back shelf support rail directly into a stud or drywall anchor and enjoy!!

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