Ever since I designed the outdoor kitchen, I had plans for floating shelves on one of the 6×6 redwood beams. This particular beam would not be associated with any cabinetry so it needed some form of artistic design. Originally, I thought that redwood slabs would make great shelves, but I was told that they will crack and weather and needed support by putting plywood on the bottom. I thought about it and chose to go with metal.
I contacted an artistic welder in July 2016, but he took too long so I was given the recommendation of Jordan Booth, an expert welder.
I am really glad that Jordan was interested in my project because he picked up on my style and preferences of rustic metal and the desire to use horseshoe brackets.
I took a big piece of cardboard to make the template pattern. I used a small piece of the redwood post to size the opening and traced it out before cutting the hole in the center. I gave the template to Jordan to make 3 shelves. Luckily, my farrier, Mike Hayward gave me 24 metal horseshoes to use for the project.
Jordan and I discussed the type of metal to use for the shelves. I had taken some photos of a counter top that I thought was thick and good quality. I had even called the person who made this counter, but I never got a call back. Fortunately!
Jordan and I decided that flat sheet metal was not the best option, and it would be more authentic and cool to use recycled metal from a car or truck. On a whim, I decided to visit a car junk yard in Santa Cruz, thinking that I could use car hoods.
After thinking about it, I did not want to use car hoods because they are painted and curved. I need rusty and flat shelves. Jordan called with great news, he had a 1950 Ford flatbed truck from Petaluma that could be cut into 3 shelves with a cool pattern. I was instantly sold on the idea!
An idea made out of cardboard to rustic reality!
On January 6, 2017, Jordan welded and installed the shelves with horseshoe brackets.
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