Closet Shelves The closet shelf is 5'-7" x 12" which is longer than the precut stock shelves you can buy at a home improvement store so I cut the shelves out of a 4x8 piece of melamine. A 4x8 sheet of 3/4 melamine is heavy and unwieldly so I had to lay it on the ground and cut it up with the Skill saw. You'd need a really large extension on your table saw to cut a 4x8 sheet. If you know your measurements and buy the boad at Home Depot you can have them make a couple of cuts to get the board down to size. Once I had smaller managable pieces I was able to cut them on the table saw.
Trimming out the Closet The closet shelf is 64" above the floor. I used a level to lay out and nail/screw 3 pieces of 1 x 4 trim called cleats to the closet walls for the shelf to sit on. I always locate and nail into studs. The 1 x 4 pine trim boards actually measure 3/4 x 3-1/2".
Shelf Bracket I nailed in vertical trim pieces for the shelf brackets.
Side Shelves I cut the shelves to the correct width less about 1/8" for wiggle room (out of square walls). I found the studs and laid out and nailed / screwed shelf cleats to the right wall for 3 shelves. What I did to get the shelves level is place a shelf on the right side cleat with a level on the top. I leveled the shelf and scribed a line under the shelf on the left side. I nailed the left cleat in even with the line. I placed the shelf and scribed a line along the back to position the rear cleat. You don't need the rear support cleat unless you are going to load up the shelf. I happened to have a bunch of excess wood so I did the back.
Paint Touchup There were a few pencil lines, nail holes and ends that I painted over.
Shelf Bracket I leveled the shelf brackets and screwed them into studs with 3" wood screws. I drilled pilot holes because one screw was so tight it broke off in the hole.
Shelves Since everything was cut from a large sheet of melimine the edges are unfinished. I painted the front edge of the long shelf white.
Closet Rod I measured across the closet taking in account the thickness of the rod flange supports I'm putting on the ends. I bought a 6' steel rod that I had to cut down. I wrapped it in tape to keep it from getting scratched up.
Closet Rod I wanted a square cut so I used a miter box and a hacksaw. The best tool would be a metal chop saw.
Closet Rod I cleaned up the cut on a bench grinder.
Fixing a Mistake I have a problem. When I dropped the pole in place the side wall cleats didn't extended far enough to meet the rod.
Fixing a Mistake When I originally installed the cleats on the ends of the closet I didn't extend them long enough to get behind the end of the rod. I got some 1 x 3.5" pine and am replacing the shorter pieces.
Fixing a Mistake I pried off the original cleats by slipping a paint scraper under them and lifting. Then I painted over the mistake. I marked the stud locations on pieces of masking tape.
Screwing in the Cleats Using a longer board ensured that I hit more studs. I made sure the board was level and flush with the bottom of the closet shelf when I drove the screws.
Closet Pole End Flanges With the pole in position I marked the location of the pole end flanges and screwed them in..
The Pole is in
Edging the Shelves Run the edging tape out along the edge and cut it to length with a scissors. It can be a little longer because it will be trimmed later.
Edging the Shelves Position the tape on the edge so one side is flush with the surface of the shelf. Tack one side on with the iron and make sure the rest of the length is flush with the surface. Run the iron along the edge making sure it's flat on the edge. Go in one direction so all the slack is taken out. Once the tape is in position let the iron sit over one spot for about 30 seconds. Then move the iron along the tape so it can sit on another spot. This makes sure the heat glue really soaks in.
Edging the Shelves Remove the iron and run a smooth block of wood across the edge pressing it down. This ensures a good solid bond.
Edging the Shelves Let the work cool for about 10 minutes. Flip the shelf over so the overlapped edge is exposed.
Edging the Shelves Place the shelf on a scrap piece of wood and carefully run a sharp razor knife along the edge and shave off the excess.
Edging the Shelves Take some fine sandpaper or a drywall sanding block and lightly sand the edges at a high angle to remove any excess edging and glue the trimming didn't take off. This also smooths the edge.
Edging the Shelves Your shelves are done and now have a nice factory edge. If you want you can run in a couple of wood screws in from the top to secure the shelves to the cleats.