There’s something magical about building a piece that not only displays a collection but becomes part of its story. Today, I’m sharing how I built a custom shelf for a train collector—complete with a tunnel feature that lets the display interact with the trains themselves. These floating shelves were a fun build. The client wanted to have one of the shelves equipped with a custom train tunnel for his 1950’s 1950s-era model train. I built this for a home office, but how great would it be to have a model train running around your breakfast nook?
The overall shape of the design is inspired by part submarine, part Star Wars ship, made from walnut.
Before starting this project, I visited Colorado’s mining museum to see an old steam engine in action. The experience was inspiring and got me excited to head back to the shop and create something special.
For more information on this build, please visit my Colorado Custom Made Furniture website
Some of the specialty tools I used (affiliate links)
• Whiteside Spiral Pattern Bit https://amzn.to/2spe5eH
• 1/2″ Spiral Flush trim pattern bit https://amzn.to/2NQdWuK
• West Systems Epoxy https://amzn.to/340xKD4
• Minwax wipe on poly https://amzn.to/2AWjMWO
Step 1: Mill Your Lumber and Cut to Length
Start by milling your lumber flat and square, then cut all your pieces to their final lengths. You’ll need vertical supports and three shelves at different depths to create visual interest.
Step 2: Create the Joint System
This shelf uses a clever combination of half-lap joints and bridle joints to connect the shelves to the vertical supports, creating both strength and a clean look.
Routing the Bridle Joints
Build a jig that’s the exact thickness of your shelves. The key innovation here: make the sides of the jig the same width as the space between your shelves. This allows you to use the same jig as both a routing guide and a spacer for perfect shelf placement.
Using a pattern bit in your router, cut out the bridle joint portions on one vertical support. Since the router bit is round, you’ll need to square up the corners with a chisel before moving to the next position.
Transferring Locations to the Other Support
To ensure your shelves are level, you need identical dados on both vertical supports. Here’s the trick: use your pattern bit to start a shallow cut on the second support, just deep enough to create a registration point. Drop a piece of wood into this shallow dado, reset your jig against it, and rout the full dado. Square up the corners with a chisel as before.
Step 3: Cut the Half-Lap Joints
To prevent routing too far when creating the half-lap portion, cut spacers and secure them in place as stops. Head to the router table and rout out all the space for the half-lap joints on each shelf.
Even though each shelf has a different offset from the vertical supports, set up a stop block on your miter gauge. This adds stability and makes the cuts safer and easier to align.
Step 4: Ensure Consistent Shelf Spacing
Make a plywood story stick with two notches cut at the exact distance between your vertical supports. Use this to set up your stop block for each of the three shelves. This ensures the spacing is identical on every shelf—critical for proper assembly.
Pro tip: Do a dry test fit at this point to confirm everything aligns properly.
Step 5: Add Structural Reinforcement
While the shelf is test-fitted, create a jig that clips over the shelves and around the supports. Using a collar and plunge bit, rout mortises for floating tenons. These will strengthen the vertical supports in the areas weakened by the shelf dados. Work your way around each joint systematically.
Step 6: Install the French Cleat System
Switch to a different jig to rout a slot in the center of each support for a french cleat. This hanging system is incredibly strong and allows for easy installation.
Smart move: Save this jig. When you’re at the installation site, you can hold it against the wall to mark the exact location for the mating cleat piece.
Square up the routed slot with a chisel for a clean fit.
Step 7: Add Decorative Arches
Pull the shelf apart to work on decorative details. Cut arches on the fronts of the support pieces to add visual interest.
- Create a plywood template on the band saw, adjusting until you’re happy with the shape
- Smooth any jagged edges with a flexible sanding strip
- Rough-cut the supports on the band saw, following your template
- Attach the template to each support with double-stick tape
- Use a flush-trim bit to route the supports perfectly flush to the template
Step 8: Create the Tunnel Feature
This is where the shelf becomes truly interactive with the train collection.
- Make a plywood template in the shape of your tunnel opening
- Hog out most of the waste material at the drill press
- Do the final cleanup at the router table
- Cut trim pieces for the tunnel (I used a small CNC, but a scroll saw works great)
- Drop a piece of scrap wood into the shelf slot to help align the trim piece to the bottom edge
- Glue the trim in place, intentionally cutting it oversized
- Once dry, flush-trim it at the router table for a perfect fit
Step 9: Final Assembly
With so many parts to glue simultaneously, epoxy is your friend—it provides plenty of working time to get everything positioned correctly.
- Glue up the main shelf assembly
- Cut stock for floating tenons and the French cleat
- Glue and screw the French cleat into its slot
- Round over the floating tenon edges at the router table
- Glue the floating tenons into their mortises
Step 10: Finishing and Installation
Apply your finish of choice (I used polyurethane for durability). Once dry, install the mating French cleat on the wall at your client’s location and hang the shelf.
The Result
The finished piece doesn’t just display the train collection—it interacts with it. The tunnel allows trains to pass through the shelf itself, making the display part of the story rather than just a static showcase.
This project demonstrates how thoughtful jig-making and careful planning can create complex joinery that’s both strong and repeatable. The combination of traditional joinery techniques with modern touches creates a piece that’s built to last and looks fantastic doing it.
I’m the owner of Benham Design Concepts, a mixed media art studio where I design and build custom furniture and other works of art using wood, glass, stone, and various metals.
In this blog, I talk about the art I create, my journey, and the things I learn along the way.