Old Door + Fallen Branches = Shelves!

To go with our forest theme, as well as to be consistent with our habit of upcycling materials for our nursery, we decided we needed shelves that made creative use of something old and also had something woodsy. We kicked around several options and I poured through pinterest photos looking for the perfect idea. I saw several shelves held up with rope that I really liked, rustic looking but a bit too beachy. Tom had the idea to use branches as braces.

Tom also thought it would be cool to make use of an old door for the shelves instead of buying regular shelving. We found this one at The ReBuilding Center here in Portland.  Old is in many ways synonymous with quality and craftsmanship in the world of construction. This door is solid wood through and through.

Tom cut the door in two pieces.

Safety Tip: Materials painted before 1978 are likely to have lead paint so be sure to read up on it and take the necessary safety precautions!

He then cut each piece of half lengthwise.

We painted the shelves with several coats of polyurethane to seal the paint and provide a wear resistant finish.

For the supports I found fallen pine branches on my walk home from the bus stop.

Tip: Use a portion of the branch to rub and knock off all the loose bark.  This will save the mess inside and reduce the flaking of the bark after the shelves are in use.

We mounted the backs of the shelves to the wall using long screws anchored into the studs.  The shelves are leveled and temporarily held in place using a piece of lath.

The most challenging part of this project was getting the branches cut. Living in a condo with no work shop makes projects like these challenging, but not impossible.  A piece of ply wood can be used to layout the shelving location and a keen eye and patience can be used to trim and cut the branches until they meet the wall and shelves in just the right way.

The branches with less “character” can be cut much quicker using the plywood as a guide to keep your cuts perpendicular and straight.

If you have access to a proper shop, a set of clamps, and a deep enough saw, these cuts can be made in a very clean manner. For the rest of us, we’ll use the “rustic” excuse.

After the cuts are made and the branches all meet the walls and shelves in an acceptable layout, we pre-drilled holes in everything and began screwing it all together.  We used multiple screws for redundancy where the branches were thick enough.  These pine branches were soft enough that the screws could be counter sunk and hidden in the bark.

This branch was the most challenging.  It meets the lower shelf half way up and then connects to the upper shelf in two locations.  We live on the second story and Tom was  up and down the stairs for 30 minutes trimming and adjusting.

After getting everything together, we applied another coat of polyurethane to everything.  Applying the final coat to the branches first allowed any residual bark to flake off onto the dry shelf surface instead of onto a fresh coat of wet polyurethane making for an easy clean up and smooth finish on the shelves.  The polyurethane did a great job and securing the bark to the branches.

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3 Responses to “Old Door + Fallen Branches = Shelves!”

  1. purplescript Says:

    Love this DIY design!

  2. It’s great to see someone else who loves, vintage and recycled style. Your blog is great!

  3. Lovely work!

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