Sewing Desk

Dimensions

Cut list

Tools you'll need

• ✓

  Tape Measure (5m or longer)

  Used for measuring each component.

• ✓

  Pencil and Carpenter's Square

  For marking ink lines and confirming right angles.

• ✓

  Saw

  Home center cutting service is recommended.

• ✓

  Electric Driver

  Impact driver enhances work efficiency.

• ✓

  Sandpaper

  Prepare two types: #120 and #240.

• ✓

  Level

  Essential for checking levelness during assembly.

• ✓

  Clamps (2 or more)

  Used for temporary fixation during joining.

• ✓

  Brush and Paint Tray

  Used for oil or varnish finishing.

Materials

Build steps

1. 1

   Confirm Measurements and Installation Location

   ≈ 15 min

   Measure the installation location of the TV stand and confirm that the sewing desk (1000×600×720mm) fits. Also check the outlet positions, cable routes, and the shape of the TV stand.

   Measure

   W 1000 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is TV stand width plus 100mm on both sides. Consider reinforcement at the center of the top board if wall-mounted.
   • Select a location that allows at least 50mm clearance from the wall to ensure front and rear ventilation.
   • If the floor is carpeted, the legs may sink causing instability, so measure assuming a hard board underneath.

   Watch out

   • If the TV stand depth (600mm) is smaller than the TV stand width, the TV may protrude dangerously; measure the TV box bottom surface before purchase.
   • If storing AV amplifier or soundbar, confirm the device fits inside the shelf interior dimensions (W1164×D390×H328mm).
2. 2

   Create Cut List and Order from Home Center

   ≈ 30 min

   Cut two top/bottom boards (18×400×1200), two side boards (18×400×364), and one shelf board (18×390×1164) from 18mm Lauan plywood 1×6 boards. For the back board, use one 4mm veneer (1200×400). Lauan plywood is heavy and large, so use home center cutting service recommended.

   Cut

   Use the in-store cut service

   CutSTEP 2 / 17

   Tip

   • Home center cutting service costs 30-50 yen per cut and accuracy is within ±1mm.
   • The wood grain direction looks best horizontally from the front; specify this when ordering.
   • Side boards length 364mm includes thickness of two top/bottom boards (18mm each) in internal dimension calculation; specify as is.

   Watch out

   • If plywood thickness is different from 18mm (e.g. 12mm, 15mm, 21mm), side board length calculation changes. Confirm actual thickness before ordering.
   • Cutting service only supports straight cuts; wiring holes and chamfers must be processed yourself.
3. 3

   Apply Edge Banding Tape

   ≈ 25 min

   The raw edges of plywood are rough compared to finished surfaces. Apply edge banding tape with an iron on the exposed edges: front, back, left, and right edges of top and bottom boards; front edges of side boards and shelf board. Set iron temperature to medium (~150℃) and press for 3-5 seconds.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • Edge banding tape adheres by resin melting with heat; press with cloth while still warm for better adhesion.
   • Trim excess tape with a cutter at an angle for a natural finish; cut in 2-3 passes rather than all at once.
   • No need to apply to back board (4mm veneer) edges since it is hidden.

   Watch out

   • Moving the iron continuously prevents heat from accumulating; press each point 3 seconds stationary before moving.
   • If iron is too hot, tape burns and discolors; test temperature on extra tape first.
4. 4

   Sand All Components

   ≈ 30 min

   Sand all components sequentially with #180 then #240 sandpaper. The plywood surfaces are smooth, so light sanding is sufficient. Lightly chamfer edges with #240 to avoid sharpness. Also soften edge banding tape ends gently with #240.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the wood grain to avoid raised fibers and paint unevenness.
   • Chamfers should feel smooth enough that tissues do not catch.
   • Using a sander near a vacuum nozzle reduces dust, making indoor work tolerable.

   Watch out

   • The plywood veneer is thin (0.2-0.5mm); avoid heavy sanding that exposes the grey underlying layer.
   • Sanding produces lots of dust; perform in a well-ventilated area like balcony or garage.
5. 5

   Mark Shelf Board Position on Side Boards

   ≈ 20 min

   Mark the fixed position of the shelf board on both side boards. Draw a horizontal line 200mm above the bottom edge of each side board (this indicates the shelf board top surface position). Ensure symmetry by transferring markings between the two side boards. Mark pilot hole positions along the center line (9mm from edge, half of 18mm thickness).

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack both side boards, mark one, then transfer with center punch for perfect alignment.
   • Shelf board height can be adjusted; add about 50mm above AV amplifier height as reference.
   • Pilot holes should be precisely at 9mm from edge for proper alignment.

   Watch out

   • Unequal heights on side boards cause shelf tilt; always transfer marks by stacking both.
   • Pencil lines may show through paint; keep lines light for erasing after assembly.
6. 6

   Drill Pilot Holes on Shelf Board and Side Boards

   ≈ 25 min

   Drill two ø3.5mm pilot holes on each end of the shelf board for fixing side boards (total 4 holes). On the side boards, drill through ø3.5mm holes at marked positions and countersink on front side with ø8mm drill to 3mm depth. Though plywood resists splitting, drill carefully near edges and clamp before drilling.

   Drill a hole

   下穴 φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersinking screws flush creates a neat finish.
   • Use drill stops to control depth, drilling about 2mm less than board thickness.
   • Clamp boards firmly to avoid splitting, especially drilling shelf board end grain.

   Watch out

   • Driving screws within 10mm of edge risks edge splitting; keep pilot holes at 9mm line.
   • Drilling at an angle can cause protruding through the other side; drill vertically.
7. 7

   Temporary Assembly of Bottom and Side Boards

   ≈ 30 min

   Place bottom board on floor with two side boards standing on top, aligning side board bottom edges with the bottom board edges. Apply thin layer of wood glue, drill ø3.5mm pilot holes from bottom board side, and drive three 38mm coarse-thread screws per side (6 total). Use carpenter's square to confirm right angles during assembly.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Apply a thin, even layer of glue roughly the size of a toothpick tip; wipe excess immediately with damp cloth.
   • Use clamps to hold side boards firmly before drilling to prevent movement.
   • Verify bottom board is level with a level to avoid skewing.

   Watch out

   • Excess glue squeezes out and may prevent finish adhesion; keep application thin and uniform.
   • Failing to drill pilot holes before screwing can split plywood; always drill first.
8. 8

   Attach Shelf Board

   ≈ 20 min

   Insert shelf board (1164mm long) at marked position between side boards. Align shelf board ends with side boards, apply glue, drill ø3.5mm pilot holes from side board outsides, and drive 2 screws (38mm) per side (4 total). Use a level to confirm shelf is horizontal.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf board length 1164mm equals top board width 1000mm minus twice side board thickness 18mm; verify measurements before proceeding.
   • Shelf board is inside so countersinking screws is unnecessary.
   • If converting to adjustable shelves, drill multiple ø5mm holes for shelf pins at this stage.

   Watch out

   • Shelf board too short causes looseness; too long causes side boards to bulge out; double check cut length.
   • Uneven shelf causes remotes and small items to roll; always verify level with a level tool.
9. 9

   Attach Top Board

   ≈ 25 min

   Place top board (1200mm wide) on the box frame, aligning its edges with side board top edges. Drill ø3.5mm pilot holes from top board, then drive six 38mm coarse-thread screws (three per side). Countersink screw heads to hide them; optionally fill countersinks with wood dowels or putty for better finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • Top board bears TV weight; adding screws (e.g. 4 per side for total 8) improves load capacity.
   • Fill countersink holes with ø9mm wood dowels to conceal seams; paint after fills to make them invisible.
   • If TV weighs over 30kg, add a 1x2 support beneath the center of top board.

   Watch out

   • Installing the top board backwards causes grain direction mismatch; align wood grain before screwing.
   • 38mm screws are adequate for 18mm thick top board; longer screws may penetrate underlying shelf board.
10. 10

    Confirm Right Angles and Diagonal Lengths

    ≈ 15 min

    Check entire box frame right angles with carpenter’s square on all four inner corners to confirm 90°. Measure diagonal lengths inside box with tape measure; diagonals should be equal within 2mm difference. If off, remove some screws, clamp frame square, and re-tighten screws.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • Diagonal difference over 5mm indicates severe deformation; must correct to fit back board.
    • Clamping the entire box diagonally is effective to achieve precise right angles.
    • Widening pilot holes to ø4mm creates adjustment allowance allowing easier correction.

    Watch out

    • Ignoring frame distortion will cause large gaps when installing back board.
    • Use trusted accurate carpenter’s square (aluminum or steel); plastic ones have large errors.
11. 11

    Attach Back Board

    ≈ 15 min

    Attach 4mm veneer back board (1000×720mm) to rear of frame. Fix with staples from a stapler gun or fine screws (ø3×20mm) at edges and center: staples every 30mm, screws every 100mm. Back board stabilizes right angles, eliminating most frame distortion.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If frame was distorted, clamp and correct during back board installation.
    • Stapler gun uses fine pins similar to a stapler; faster than screws.
    • Install grain of back board horizontally for a neat appearance on TV stand.

    Watch out

    • Avoid installing back board reversed; surface and grain differ front and back.
    • Missed staples may protrude; check rear surface by hand after fastening.
12. 12

    Make Cable Routing Hole (If Needed)

    ≈ 15 min

    Use a 50mm hole saw to drill a cable routing hole in back board to pass TV power cable, HDMI, and antenna cables. Ideal hole location is directly behind TV’s connection terminals. If no hole saw, drill multiple holes with a drill and connect with a coping saw.

    Drill a hole

    下穴 φ3.5mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge banding tape to hole edges to prevent finger injury and protect cable coverings.
    • Check TV connector layout before marking hole position to ensure cables pass straight.
    • Align hole height with outlet height for a tidy look.

    Watch out

    • Misplacing hole prevents cables from exiting directly behind TV, causing unattractive routing.
    • Hole saw slipping causes plywood surface delamination; ensure center drill bit bites firmly.
13. 13

    Prepare Surface for Painting

    ≈ 15 min

    Before painting, lightly sand entire surface with #240 sandpaper. Remove dust completely with wet cloth followed by dry cloth. Remove any excess glue and burrs around screw holes. Suitable indoor finishes include Watco Oil, Briwax, or water-based paint.

    Sand

    #240

    SandSTEP 13 / 17

    Tip

    • Always test paint on scrap wood; plywood absorbs differently than solid wood, resulting in unexpected color intensity.
    • Water-based paints can be cleaned with water; recommended for beginners.
    • Watco Oil offers a natural wood grain finish; apply by rubbing with a cloth.

    Watch out

    • Glue spots repel paint; lightly sand (#240) these areas before painting.
    • Remaining dust causes rough surface; clean thoroughly before painting.
14. 14

    First Coat of Painting

    ≈ 30 min

    Apply paint with brush or cloth over entire piece in order: top board, side boards, bottom board, back board, working from large surfaces to small. Brush in one direction along grain to minimize brush marks. Apply thin and even coat; allow to dry naturally for 2+ hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Divide paint into small portions; leaving cans open forms skin and ruins remaining paint.
    • If brush marks are an issue, use a mini foam roller for smooth application.
    • Dry in a dust-free area, avoid fans or direct airflow which can cause defects.

    Watch out

    • Thick coats cause uneven drying and peeling; thin coats applied twice are correct method.
    • Heating air flow causes surface to dry but interior remains damp; always wait for natural drying.
15. 15

    Intermediate Sanding and Second Coat

    ≈ 25 min

    After first coat is fully dry, lightly sand surface with #320 sandpaper to smooth roughness, then remove dust and apply second coat. Apply thinner coat than first; this yields streak-free finish. Allow to dry for 24+ hours.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Intermediate sanding removes surface roughness without removing paint film.
    • Second coat should be thin to avoid drips.
    • Avoid touching wet paint to prevent fingerprints and dust; adhere to 24-hour drying time.

    Watch out

    • Over-sanding removes paint film; light sanding with #320 is key.
    • Thick second coat increases drying time and delays next steps.
16. 16

    Attach Leg Pads and Anti-Tip Hardware

    ≈ 20 min

    Apply felt pads to bottoms of legs to protect floor and prevent wobble. For earthquake safety, mount anti-tip straps or hardware at upper rear, fastening to wall studs with screws. Securing to wall prevents TV stand from toppling during strong shaking.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads cost around 50 yen each at hardware stores; 10mm thick pads absorb floor unevenness.
    • Anti-tip straps are available at 100-yen stores; specialty sets cost about 1000 yen but offer better safety.
    • Fix to wall studs; attaching to gypsum board alone is ineffective.

    Watch out

    • Omitting felt pads causes floor scratches and damage.
    • Skipping anti-tip hardware risks TV stand and TV falling in major earthquakes.
17. 17

    Final Inspection and Installation

    ≈ 20 min

    Carry completed TV stand to installation site; use level to confirm front-to-back and left-to-right levelness. Adjust felt pads to fix wobble. Place TV and route cables through back board holes. Power on devices to check function. Avoid loading heavy items first day and allow paint to fully cure over one week.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Place TV centered on top board to distribute weight evenly; placing near edges may cause warping.
    • Route cables neatly through back board hole and bundle with cable ties for clean appearance.
    • Leave 50mm ventilation space front and rear when storing AV amplifiers or BD recorders on shelf.

    Watch out

    • Paint takes one week to fully cure; placing remotes or devices directly on paint too soon causes stickiness.
    • Sloped floors prevent leveling; adjust felt pad thickness accordingly on each side.

Warnings

• ⚠️Drill pilot holes before driving screws to prevent wood splitting.

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