Acoustic Panel Shelf Bracket

This is a low-profile shelf bracket made for 7 3/4" wide shelves.   It was designed to be low profile and thus needs to be reinforced with a 3/16" thick round rod.

Ingredients

• PLA or PETG

• 3/16" cold rolled round rod: https://www.menards.com/main/hardware/sheet-metal-rods/steelworks-3-16-x-48-cold-rolled-steel-solid-round-rod/11630/p-1444432403702-c-9215.htm

  • Get cold rolled, it's stiffer than some of the other stuff you might find

• #8 Course Drywall Screws:  https://www.menards.com/main/hardware/fasteners-connectors/screws/drywall-screws/grip-fast-reg-8-x-2-phillips-drive-bugle-head-coarse-thread-drywall-screw-1-lb-box/229-2858/p-1444441850481-c-8930.htm

• #6-32, 1/8" toggle bolt, 3" long:  https://www.menards.com/main/hardware/fasteners-connectors/anchors/toggle-bolts/grip-fast-reg-6-32-x-3-round-head-zinc-toggle-bolt-4-count/232-3791/p-1444451955566-c-8725.htm

  • Alternatively, get a #6-32, 1/8" toggle bolt and then get a set of flathead #6-32, 3" machine screws:  https://www.menards.com/main/hardware/fasteners-connectors/screws/machine-screws/grip-fast-reg-6-32-x-2-phillips-drive-stainless-steel-flat-head-machine-screw-6-count/16809/p-1444439727909-c-8933.htm  (these linked are only 2"!)

  • This route is much better, the model is designed for these types of screws so they sit flush.   If you get the round head toggle bolts, you will have to modify the model (Freecad file included) or use a drill to ream it out.

• #6, 3/4" wood screws:  https://www.menards.com/main/hardware/fasteners-connectors/screws/wood-screws/grip-fast-reg-6-x-3-4-phillips-drive-zinc-flat-head-wood-screw-175-count/2330131/p-9639598970066864-c-8940.htm

• These are the shelves I used: https://www.menards.com/main/storage-organization/shelves-shelving-units/shelving-boards/dakota-trade-7-3-4-x-2-charcoal-prefinished-decorative-shelf/2115871/p-12148367798687579-c-5702.htm

Installation

1. Print

   1. Give it about 7 vertical and horizontal perimeters

   2. Infill 40+%, triangle infill

   3. Print with brim if your printer is prone to warpage

2. Seat full round rod in the back of the shelf

   1. Hacksaw off the extra so it's flush with the back

3. Find where you want to place the shelf

   1. Drill a hole big enough for the toggle bolt

   2. Put the bolt through the top hole of the shelf, then attach the toggle.

      1. Now, keep in mind this screw is going through drywall, and acoustic panel, a whole inch of material, you're gonna have to press it deep

   3. Once you hear the toggle bolt open up, tighten the toggle bolt. 

      1. Hand tighten with screwdriver

      2. Do not overtighten.  The acoustic panel is made of a felt backing and you can compress it

   4. Now get the 2" drywall screws and seat them in the two bottom holes

      1. These screws will bot keep the shelf from falling out and from going it.   This will keep it ridged against in otherwise soft (felt) material.

4. Seat the shelf.

5. Place wood screw in the forward most hole.  This will keep the shelf from sliding around.