A DIY U-Shaped Mantel Shelf

PVC Pipe Mantel Shelf

• 1

  Lay the three PVC pipes out flat on a work surface. Place one PVC pipe cap on one end of each pipe.

• 2

  Place a funnel on the open end of each pipe and fill the pipe with sand. Slide the PVC pipe caps on the open ends of the pipes.

• 3

  Hold a heat gun 1-inch from the surface of each pipe, one at a time and form each length of pipe into a u-shape as the pipe heats enough so that you can bend it. Form one pipe to shape and form the other two pipes to the same shape so that they all match. Make the bottom of the “U” flat enough so that it will rest flat on the mantel shelf.

• 4

  Remove the pipe caps and empty the sand form the u-shaped pipes. Apply PVC primer and cement to the ends of the pipes and the inside edges of the pipe caps with the built-in applicators. Press the caps onto the ends of the pipes. The primer and cement will form an instant bond.

• 5

  Stand the pipes upright on a work surface, one in front of the other to form a u-shaped shelf assembly. Apply PVC primer and cement to the sides of the pipes where they join together. Press the pipes together so that the primer and cement will bond the assembly together instantly.

• 6

  Spray the assembly with an even coat of plastic spray paint. Allow the first coat to dry for 4 hours and apply a second coat. Wait 24 hours after the second coat before using the shelf.

Plywood Mantel Shelf

• 7

  Lay the cardboard flat on a work surface. Form a flexible curve ruler to create a u-shape that takes up the 12-by-12-inch space on the cardboard square. Trace along the curve ruler to transfer the curves in the u-shape onto the cardboard. This is the template for the shape of the shelf. Make the bottom of the "U" flat enough so that the shelf will rest flat on the mantel.

• 8

  Cut out the u-shape from the cardboard using an utility knife. Trace the u-shape onto each sheet of plywood using a pencil.

• 9

  Put each sheet of plywood flat on the table of a band saw and cut out the u-shape from each sheet. Guide the plywood through the saw in a steady motion just fast enough to allow the blade to cut the wood until each cut is completed.

• 10

  Stack the 10 u-shaped plywood cut-outs on top of each other. This is the shelf assembly. Apply wood glue between panel and press them together with your hands. Clamp the assembly with two wood clamps and allow the glue to dry for 24 hours. Remove the clamps.

• 11

  Sand the edges of the assembly with a fine-grit sanding pad until the plywood is completely smooth. Wipe off the dust from sanding with a tack cloth.

• 12

  Brush on two even coats of shellac with a natural bristle paintbrush. Allow the shellac to dry for 24 hours between coats. Wait 48 hours after the final coat and stand the shelf upright on the mantel.