How To Create a TV Unit

What You Need

• 2 x Pine Panels - 1800mm x 450mm x 18mm
• 4 x Pine Panels - 310mm x 450mm x 18mm
• 1 x Pine Panels - 650mm x 450mm x 18mm
• 6 x Bun feet (your choice of style)
• 1 x Plywood - 2400mm x 1200mm x 10mm (or thinner)
• 1 x 500ml Selleys Aquadhere Interior
• 1 packet 25mm wall panel nails
• 6 x 8x45mm screws
• Router and router bit 18mm or smaller
• Carpenters Square
• Hammer
• Saw
• Straight edge longer than 450mm
• 2 x (F) or (G) clamps
• Measuring tape
• Pencil
• Sharp chisel or utility knife
  
  

How To

Step 1: Take one of the full length panels (1800mm) and mark the centre of the length of the panel (900mm). Then measure and mark 320mm either side of the centre mark. From these marks, measure and mark a further 500mm on either side.

Step 2: Place one of the 310 x 450 pieces on top of the marked line, then take a pencil and draw a line on either side using a square to keep it true. This marks out the channel to be routed.

Step 3: Set Router cutter depth to 6mm (1/4”). Set your straight edge up and clamp in position so the cutter is aligned to the INSIDE of the pencil marking. If you are using a smaller router bit you will need to complete the cut in 2 or more passes. 

It’s a good idea to check the fit at this stage to make sure the cabinet cheek will fit nicely. Insert the 310 x 450 piece to ensure it fits. Better to be a bit on the snug side rather than a loose fit.

Step 4: Repeat the process for the other 3 division marks.

Step 5: Once one panel has been routed, position the other full size panel next to it (lengthways). Line up the ends, place and clamp straight edge (must be long enough to cover the 2 pieces) in position so as to allow the router to continue the previous rebate across and into the new panel.

Step 6: Select a piece of waste panel or use the 310x450 piece and place into the slot across the 2 panels. This will assist in the alignment of the remaining cuts. Use the straight edge to continue the previously routed channels across into the new panel.

Step 7: Once all 8 channels have been cut, test the fit using the 310x450 piece and place panels to one side.

Step 8: Select 2 of the 310x450 pieces. These pieces will be used as shelf supports. Measure down 90mm. Router a channel across the panel. Use the same router settings as previously.

Step 9: Position these 2 panels upright into the middle slots of the large panel you have chosen as the base of your unit. Have the 2 cut shelf rebates facing inwards with the channels on the topside. Stabilise the uprights and make sure they are at 90 degrees to the base.

Step 10: Measure the distance between the bottoms of the 2 slots just cut for the shelf support. Transfer that measurement accurately to the spare panel 650mm and cut to size.

Step 11: Do a dry fit. Place the 2 inside supports into middle rebates, slide in shelf to shelf rebates. Position remaining 2 end supports into base. Place top panel into place and push down onto support uprights. Check for squareness all round and flushness of joints. Make any necessary adjustments and once happy disassemble and glue up. 

Step 12: Start with the centre pieces. Glue in the shelf using Aquadhere Interior, wiping off any excess glue squeeze out with a damp cloth. Be sure to remove all traces of glue as it can inhibit the staining or finishing process later on. Put to one side making sure to keep it square.

Step 13: Glue in and fit 2 end supports onto the base. Tap home with a sacrificial piece of wood and a hammer or mallet.

Step 14: Repeat step 13 on the centre piece with the shelf in position and the other end panel. 

Step 15: Apply Selleys Aquadhere Interior to the tops of each upright. Place the top panel of the unit in place. Tap home with sacrificial wood and mallet or hammer. Wash off excess glue with a damp rag. If joints are loose then hold in place (making sure each upright is square) with some sash clamps until glue has set.

Step 16: Measure the outer edge height and width of the unit and subtract 5mm from each measurement.

Step 17: Use these measurements to cut the piece of Plywood or backing material to size.

Step 18: Turn the unit over so the face side is resting on the bench. Use a blanket or something soft to protect the surface. As a guide use some masking tape to show where the internal supports run so when the back is in place you can nail with accuracy.

Step 19: Apply a thin bead of Selleys Aquadhere Interior to the rear frame of the unit.

Step 20: Line up the bottom edge of the back panel to the bottom of the base of the Unit. This will leave a slight gap from the top of the unit to the backing board which is desirable. For extra security hammer in some thin wall nails approx. 400mm apart over the frame. Turn the unit over so that it is lying on its top.

Step 21: To attach feet, apply a bead of Selleys Aquadhere Interior to the inner section of the foot.

Step 22: Place the feet into position. Using a piece of scrap wood as a gauge set the feet one thickness in from the front and side edge of the Unit.

Step 23: On the rear or unseen side of the unit the feet have been placed right on the edge of the base. On the front side of the unit a gap has been left to the edge (18mm) so the feet are not as visible. You may find it necessary to secure the feet into position using a screw in the centre of each foot. 

Step 24: If you do this remember to take into consideration the length of the screw used and use one that will hold the foot on but not exit the top of the panel above.

Step 25: Allow the unit to sit until the glue has set. Move into position, fill it up and enjoy.