We're making this ironing board storage rack and shelf out of pre-determined lengths of galvanised pipe and galvanised fittings. Because the shelf is going to be carrying a bit of weight, you need to make sure that it's the right width so that it can be anchored to the wall studs. The measurements provided in this project are based on studs that are 500mm apart.
Measure and mark the 15mm plywood for the shelf. Make sure it's wide enough and long enough for the iron to sit on. Our shelf measured 400mm x 170mm. Put on your safety glasses, earmuffs and dust mask. Clamp the ply to the workbench and cut it with the circular saw.
Because the shelf will be supported by the galvanised pipe, you need to drill a hole in the plywood wide enough to fit the thickness of the pipe and one of the 15mm elbows. Where you put the hole will depend on the design of your shelf and the size of your iron. Put on your safety equipment, clamp the ply to the workbench and, using the 32mm spade bit, drill a hole.
It's a good idea to do a dry run and lay out the pieces in the design of your choice. Clamp one flange to the workbench to give you a starting point. Place the other flange at the desired width, which in our case is 500m. Then use a combination of joints and different lengths of pipe to get from one flange to the other. For example, working from the top, we started with a flange, then screwed a 100mm pipe, an elbow, a 150mm pipe and a 200mm pipe.
For the ironing board holder, which will be on the same level as your other flange, we started with a length of 100mm pipe and screwed it into the flange. We then screwed an elbow onto it. Working across to the left, screw a 100mm pipe, a T, a 100mm pipe, a T, then a 100mm pipe then an elbow. When using the Ts for this section, make sure they are facing the opposite way to the flange and the final elbow is pointing up. Attach the brass end caps to the ironing board holder. When building the storage unit, remember to leave space for the shelf and plenty of room to hang your ironing board when putting your final design together.
Now it's time to get creative with paint. First, remove the shelf from the unit. We spray painted our pipes black and the shelf a bright yellow. It's also worth spray painting the screws and saddle clamp black so they match.
Once the paint is dry, put the shelf into place on the storage unit. Secure it to the pipes using the cordless drill, saddle clamp and the 20mm screws.
Use the stud finder to locate the studs in the wall where you're going to attach your ironing board storage rack and shelf. Use the 20mm screws to attach the unit to the wall.