Custom floating desk build - rexehuk

rexehuk · 8 Oct 2011 at 19:35

Hello all!

Today I've started work on my new desk, this will be replacing an Ikea galant corner desk.

This post will serve as a mini build log (should be a few days long). All photos sponsored by Samsung S2

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Specifications of desk:

1.84M long
600mm deep
38mm thick

The desk

Making the framework

Firstly I had to mark out the framework for fixing to the walls, this will be what the desk rests on out of sight.

Forgot to allow for the thickness of the backplate for the side brackets

derp.

Bench saw soon fixed that

Drilled the initial pilots for the back/side brackets

Next had to mark out the notches for the steel support to sit in

Then sawed and chiseled out the notches

rexehuk · 8 Oct 2011 at 19:35

Next step is onto the steel!

25x25x3 Box Steel, all rubbed down with thinner and sand paper to ensure it was free from oil.

Due to the kind of steel, I need to coat it to prevent it rusting, I chose this as it had no need for primers / undercoats.

First coat on

Third coat on

Well deserved rest

I've decided to build some cable management system to the underside of my desk... Everything I've looked at is extremely expensive, so I've made my own!

Next step is fitting the wood to the wall and then the joyful job of cutting the worktop to fit onto walls that are not straight. That may take place tomorrow time permitting.

The wooden brackets need to be painted or vanished, I'm yet to decide a decent colour.

rexehuk · 8 Oct 2011 at 20:43

macmodder said:
did you buy the work top especially or did you have some left over from a kitchen you've just fitted?

Bought it for the project. It's 3 meters in length so I may well make a little shelf with the remainder for the printer, server and switch.

Also got some chrome cable grommets on the way, shall post pics when they arrive.

rexehuk · 9 Oct 2011 at 16:30

UPDATE

A quick update on the progress, desk is coming along nicely! It's all fitted for now, but some work to do yet (as well as repairs).

First of all I started opening up the holes for the back bracket (the strongest fixing) with 7mm drill bit and 10mm for the wall plugs.

Marked up the wall for the bracket(s) to sit, found this quite hard as to judge the level I wanted the desk to sit at, however I'm fairly happy with the height it came out at.

Success!

Then fitted the right hand fixing, this has an overhang as the wall its fixing into the chimney, fitted 3 fixing points with 2 screws each for extra stability

Then the left fixing

As the walls are not straight, I had to deduce the amount the walls were out, which is where this tool comes in handy.

In true father son spirit, I delegated the work and took a management role ^^

First fitting... did not go so well, as it turned out the right wall was 90 degrees for a short distance and then bulged slightly causing the measurement to be a very tight fit.

The solution? Destroy! This will be touched up after with filler and special caulk.

Now it fits

Then in with my big black rod, and marking out the top end screw points to fix into the brackets

Drilled out the holes on the topside and underside (for fixing into desk)

Countersunk

Fit the steel brace and the desk is secure

Some magical cleaning later with a hoover

That is all for now, the next steps in the project are

Fixing the wall
Applying the edging to the desk
Painting and shaping the support brackets to make them a bit nicer
Fitting 3 x 80mm chrome cable management gromits (I lack an 80mm hole cutting bit so need to buy one)
Buying a nice chrome plug socket
Fitting cable management system
Fixing power sources to the underside of the desk so that end end result = 2 cables only into sockets
Setting up all my gear on the new desk

rexehuk · 9 Oct 2011 at 17:34

panyan said:
can i add something to the to-do list?

i suggest you screw one of those multi-plug power surge extension cables to under the desk so that you dont have a bunch of cables coming from the power socket?

one of these

Already got 2 surge protection power strips, these will be fixed to the underside of the desk.

Hades said:
Good idea with the cable management. How do you get the cables through the desk as I can't see any holes for them?

No holes have been drilled yet as I lack an 80mm bit.

rexehuk · 9 Oct 2011 at 18:25

Hyburnate said:
Looks... Amazin, but my mother says it wont take the weight xD

Elaborate? Does she not like my big black rod? Maybe I'll show it to her sometime

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The rear mounting board is fixed in with anchor bolts to a main adjoining wall to the house next door, the house will come down before the desk

. The left support is fixed in to the main exterior wall the the front of the house and the right is fixed into the chimney, which is my weakest point due to the overhang.

It is also worth noting that the main weight will be on the right edge (where the PC will probably sit) which will be close to the fixing point to ensure the least amount of strain on the desk, and along the back of the desk where the monitor will sit; I can't see any issues.

The weakest point in the desk is between the rear brace and the front steel support, that area will have no significant weight placed upon it.

If it does fall down I'll give your mother kudos

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Hyburnate said:
I'd keep walking into it, I'd have a red hip by the end of the week

Haha luckily this is not a scenario. The edge is next to my mirror, I will give a full room view once it's done, my room is fairly large. I did however do this a few times with my Ikea galant corner desk, which ended in me nearly in tears each time.

Also I'll be happy to hear anyones ideas on how to finish off the wood to make it a bit more stylish. I was thinking of painting it black and shaping it to some degree... need some inspiration. You'll see why I want black when I show the rest of my room (Ikea mad).

rexehuk · 9 Oct 2011 at 19:19

Hades said:
It looks like it will take the weight fine to me.

As for finishing the wood I assume you mean the support on the right hand edge that sticks out... weell, you could either cover it in a veneer, or shape it so that it tapers off towards the edge, then veneer it.

Veneer is a good idea, never thought of that. It would work well due to the surface of the desk and the fact finding a suitable paint / varnish will be impossible.

As for the shaping, yeah I mean the right one sticking out, if I go the veneer route I can coat the brackets in veneer too, it seems to come in massive sheets for cheap.

I was thinking a simple rounded edge to a tip, could be a simple way to make it look nicer. Luckily I have a good bit of the same wood left, so can use that for practice runs.

rexehuk · 9 Oct 2011 at 20:54

Tealc said:
Climb up on to the desk and lie across it/sit on one edge and see if it holds your weight and take a picture to prove these naysayers wrong. If it holds a grown human's weight then a pc should be a doddle.

You're on buddy. I don't have Hovis... Warburtons will have to do.

rexehuk · 9 Oct 2011 at 21:00

Hyburnate said:
I'm sorry, whats with the bread?

OcUK can answer that.

Hyburnate said:
How many monitors do you have?

2 x 23"

rexehuk · 9 Oct 2011 at 23:30

Nightglow said:
Use 'Dado Trunking' much neater you can add extra sockets, network port. etc.

http://www.tlc-direct.co.uk/Main_Index/Trunking_Pvc_Index/Dado_Trunking/index.html

I have use it along the back of my desk.

Looks a bit too officey for me! I hate the plastic finish. I somehow don't think it will match my chrome fittings

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Network ports are not a huge deal, I have a switch in my room for all that, I'll see how the cable management is once it's all completed, if I can be bothered I may take extra steps.

It's worth noting that this project is already quite costly

, so trying to avoid massive extras on top now.

rexehuk · 9 Oct 2011 at 23:36

Hyburnate said:
;D You got your things on it yet? ;D

Just a monitor / kb / mouse and my server. Can't put anything on the desk... as there is no holes to feed the cables, so just tucked away in a corner of it at the moment.

Going to be a few days until my next update

. I imagine there will be a few niggles that stop me in my tracks, such as monitor cables too short, usb cable too short etc etc.

I may have to ask OcUK for a donation of cable extensions when the time comes :rolleyes:

. Or maybe OcUK will be nice enough to sponsor me some as a loyal customer for many years

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rexehuk · 11 Oct 2011 at 11:36

Gentleman... I give you 3 discs of awesome.

80mm bit has arrived too.

rexehuk · 11 Oct 2011 at 11:42

panyan said:
mmm, i like a bit of chrome and wood

I'll give you some chrome on wood shots after my cuppa. Not quite sure when I'll fit these yet, ideally I need to style the supports before I fit these and fix the desk down for good.

rexehuk · 11 Oct 2011 at 11:59

As promised, some more shots.

Worth noting these are not done on a galaxy s2

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rexehuk · 12 Oct 2011 at 14:00

meh? said:
Looking great!!! when your done your welcome to come up here and build one for me

Cheers!

Cleaned out all of my machine during the downtime in prep for it going on the desk. Got a nice 30c drop in idle temperatures so it looks like CPU cooler wasn't down properly which is good news!

Going to do some test cuts today with the hole cutter before I man up and take on the real desk.

rexehuk · 12 Oct 2011 at 14:34

First test cut done, using an 18V matika drill seemed to do the job nicely! Luckily had an arbor laying around.

Hello there! Yours truly in sexy chrome.

Drilled with an 80mm bit, makers suggest 79mm +/- 1mm, it fits in nicely but isn't snug, so I will inject some silicone I think around the base gaps.

Not sure when I'll do the holes in the real desk as someone in the family has died... so house will be filled with relatives for the rest of the week.

rexehuk · 12 Oct 2011 at 16:23

tidusjar said:
Your project is coming along now!

Sorry to hear about your loss. Hope everything is ok with you and your family.

Cheers mate. Not really that sad, she was 90+ so not like she had a short life! I don't want to live till 90 that's for sure. "She had a good run" as they say.

Hopefully the project will be tied up by next week, we shall see.

rexehuk · 12 Oct 2011 at 16:52

Hyburnate said:
I'm with Joe

http://www.ebay.co.uk/itm/80mm-Brig...-Desk-Tidy-Brush-/370309824380#ht_2095wt_1270
****ING HELL!

Don't buy the grommets from that link, please message in trust and I can get you a 10% discount + each grommet is £14 with free postage.

Thanks for all the kind words!

rexehuk · 12 Oct 2011 at 17:11

Hyburnate said:
http://www.ebay.co.uk/itm/60MM-CHRO...ssories_SM&hash=item20b3e005de#ht_1622wt_1037 Much cheaper

Aye I saw those, they take over a month to get to you though (Hong Kong seller). Also I need 80mm due to the amount of cables I'm putting through them.

Not the cheapest way to fill my desk holes, but I'm really blown away by the quality of them. Did have to think twice when I hit the buy button though

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Family are not coming over until tomorrow evening, so I may get the desk off in the morning and get these holes done, as well as the cable management system.

rexehuk · 12 Oct 2011 at 20:22

I have a surprise! Decided to get some drill time in tonight, it's only about 1-2 mins per hole so I thought I'd drill it mounted to stop me getting loads out equipment out tomorrow.

First one fitted

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Time to cause more mess!