This project was built and designed by Brett from Brett’s Basement Woodshop. It showcases a smart, lightweight method for building rustic floating shelves that look like solid beams but are easier to make and hang.
By combining reclaimed lumber, creative joinery, and a hidden mounting system, Brett’s approach avoids the pitfalls of traditional floating shelf builds. The result is a durable, attractive shelf that preserves the character of old wood while keeping the design simple and sturdy.
Watch the full video and subscribe to Brett’s channel:
The Challenge with Reclaimed Wood
Reclaimed wood has unmatched charm but can be unpredictable. Years spent outdoors often leave it warped, dirty, and difficult to flatten completely.
Brett begins by thoroughly cleaning each board to remove grit and debris—a step that’s especially important when working indoors during winter. This prep not only protects your tools but also ensures a smoother build process.
Even after cleaning, the boards often have only one usable flat face. Rather than waste material, Brett embraces this and works with what the wood gives him, adjusting the process to highlight its imperfections while still ensuring stability.
Resawing and Laminating for Maximum Yield
To get the most out of each reclaimed board, Brett uses resawing—cutting thick lumber into thinner slices. This gives him multiple usable faces from a single board.
He then laminates those thinner pieces onto plywood, creating flat panels that look like solid timber. This technique keeps the rustic look while improving stability and cutting down on material waste.
Using this method, Brett turns old, gray-weathered boards into clean-faced shelving components. The plywood core adds strength, while the reclaimed wood faces preserve the character that makes these shelves stand out.
Unique Joinery with a Router Bit
A standout feature of Brett’s method is his use of a glue-line router bit that creates interlocking puzzle-like edges. This joinery simplifies assembly and provides a strong connection with minimal clamping.
The bit Brett uses isn’t expensive, making this a budget-friendly trick worth adding to any woodworker’s skill set. He notes three key setup factors—material feed direction, bit height, and cut depth—that ensure a clean and consistent joint.
This puzzle-style edge makes it much easier to align parts during glue-up, especially when working with warped or irregular stock.
Mitered Corners and Wall Fit
To create a seamless, beam-like appearance, Brett cuts the ends of the panels with miter joints. These give the shelves a polished, boxed look and allow for better grain matching at the corners.
He also bevels the edges of the panels that meet the wall. This minor adjustment compensates for wall irregularities and ensures the shelves sit flush without gaps.
By focusing on both structural fit and visual alignment, Brett creates shelves that look like they were built into the wall from the start.
Adding Internal Support
To reinforce the shelf structure, internal blocking is added. These supports are hidden inside the shell and prevent sagging, especially important if the shelves are used to hold books or other heavy objects.
The blocking adds strength without visible hardware, keeping the aesthetic clean and maintaining the illusion of a solid timber beam.
Glue-Up with Precision
Assembly is done one piece at a time, with Brett applying glue carefully to avoid squeeze-out. He works methodically to keep seams tight and surfaces clean, minimizing the need for post-assembly sanding.
After the glue cures, any slight overhangs or misalignments are trimmed using hand tools. Brett also adds subtle texture with chisels and scrapers to match the weathered look of the wood faces.
This careful finish work ensures that no glue lines are visible, and any repairs blend naturally with the rustic texture of the reclaimed wood.
Hidden Mounting System
Rather than using metal brackets or visible supports, Brett creates a hidden mounting structure that slides into the shelf cavity. This gives the shelf a true “floating” appearance and makes installation easier.
The internal mounting block is cut to fit tightly inside the shelf and is anchored to the wall studs. Once in place, the shelf slides over it and locks in snugly, creating a secure hold without hardware showing.
This system is simple to replicate and easy to install, making it a great upgrade for DIYers who want clean, modern lines without giving up strength.
Final Thoughts on the Design
Brett’s method proves that you don’t need to build floating shelves the traditional way to get excellent results. By combining smart material use, thoughtful joinery, and clever mounting, he’s created a reliable and attractive design that’s ideal for rustic interiors.
Whether you’re working with reclaimed wood for the look or the savings, this project shows how to get the most out of every board. The final result is a lightweight shelf that looks heavy and handcrafted—but is easier to build, hang, and customize than traditional beam-style shelves.
Please support Brett by visiting his website: https://www.brettsbasementwoodshop.com/.