Am building a nook in a wall for a heavy sculpture. Wall is framed by 2×4’s. I have framed the nook using 2X4’s, where the bottom horizontal 2×4 would be the support for the sculpture. The sculpture is about 35 pounds and is about 12 inches wide. Therefore, the sculpture is 8 inches wider than the 4 inch width of the 2×4. How would I construct a shelf that would look good and hold the 35 pounds? Any thoughts would be greatly appreciated…thanks…Tom
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You say the sculpture is 12" wide (I assume you mean deep--as in front to back); how wide (side to side across the alcove) is it? I would think just 3/4" finish grade plywood (oak, or my favorite, birch) would be strong enough. You could put a second layer under the lip that sticks out from the wall (if I'm understanding this correctly) and/or even add a moulding under the lip or on the edge of the lip. Edit: (Or you could just laminate two layers of 3/4" plywood for the entire shelf.) (The main thing would be to keep the shelf from tipping forward out of the wall and for that you just have to glue or screw it well at the ledger at the back.)
In any case, even a small board (1x2) under the front edge will add a lot of stiffness and strength to the shelf. 35 pounds really isn't that heavy. If you were really concerned (or if the sculpture weighed more like 100 pounds) you could build the shelf as a torsion box--plywood top and bottom and grid of something like 1x3's on edge for between the plywood and as the edge--very strong. (My favorite trick is to use 1/4" plywood top and bottom and fill between with 1-2" Styrofoam and band the edges with wood.)
If you want more advice, you can try asking your question at either Breaktime of even Knots. (Three and four over from House Chat above)
Edited 4/4/2006 7:18 am ET by Danno