Loft Bunk Desk

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring Tape (5m or longer)

  Used to measure each component.

• ✓

  Pencil and Carpenter's Square

  For marking lines and confirming right angles.

• ✓

  Saw

  Using the home center's cutting service is recommended.

• ✓

  Electric Driver

  Impact driver improves 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

   Measure and Confirm Installation Location

   ≈ 15 min

   Measure the location for the TV stand and confirm that the two-tier desk (loft type) (1200×600×1800mm) fits. Also check the position of power outlets, wiring routes, and the TV stand shape.

   Measure

   W 1200 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is TV stand width plus 100mm on each side. If wall-mounted, consider reinforcement at the center of the top board.
   • Select a location which can leave at least 50mm gap from the wall for front and rear ventilation.
   • If the floor is carpeted, the legs may sink causing wobble; measure assuming a rigid board will be placed underneath.

   Watch out

   • If the TV stand depth (600mm) is too small for TV stand size, it may protrude frontward and be dangerous. Measure the bottom of the actual TV box before purchase.
   • If storing AV amplifier or soundbar, confirm device size fits inside shelf internal dimensions (W1164×D390×H328mm) beforehand.
2. 2

   Create Cut List and Place Order at Home Center

   ≈ 30 min

   Cut from 18mm Lauan plywood 1×6 feet board: top and bottom boards (18×400×1200)×2, side boards (18×400×364)×2, shelf board (18×390×1164)×1. Back board is 4mm veneer (1200×400)×1. Using the home center's cutting service is recommended since plywood is heavy and large.

   Cut

   Use the in-store cut service

   CutSTEP 2 / 17

   Tip

   • Home center cutting service costs 30-50 yen per cut, with accuracy within ±1mm.
   • The wood grain looks best with horizontal grain when viewed from the front; specify this when ordering.
   • Side board length 364mm includes thickness of top and bottom boards (18mm×2) within internal dimensions; provide as is.

   Watch out

   • If plywood thickness is not 18mm (e.g., 12mm, 15mm, 21mm), side board length calculation differs. Confirm actual thickness before ordering.
   • Cutting service only does straight cuts; wiring holes or chamfering must be done by yourself.
3. 3

   Apply Edge Banding Tape

   ≈ 25 min

   Since cut edges of plywood are rough unlike finished surfaces, apply edge banding tape with an iron. Treat visible edges: front, back, left, and right edges of top and bottom boards; front edges of side boards and shelf board. Iron temperature should be medium (~150°C), pressing for 3-5 seconds.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • Edge banding tape uses resin that melts and bonds with heat. Pressing with cloth before cooling improves adhesion.
   • Trim excess tape by cutting at an angle with a cutter. Do not cut all at once; do it in 2-3 passes.
   • No need to apply tape on back board (4mm veneer) edges as they are not visible.

   Watch out

   • Continuously moving the iron does not allow heat to transfer properly; stop for 3 seconds per area, then move.
   • If iron is too hot, tape may burn and discolor; test temperature on leftover tape first.
4. 4

   Sand All Components

   ≈ 30 min

   Sand all components in order: #180, then #240 grit sandpaper. Since plywood surfaces are already smooth, a light rub is sufficient. Lightly chamfer edges with #240 to avoid sharpness. Also gently smooth edge banding tape edges with #240.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the wood grain; sanding against grain raises fibers and causes uneven staining.
   • Chamfer edges until 'tissue paper strokes smoothly without catching' as a guide.
   • Using a sander near a vacuum nozzle reduces dust by half, making indoor work tolerable.

   Watch out

   • Plywood decorative layer is thin (0.2-0.5mm); sanding too hard exposes grey base layer. Sand lightly only.
   • Sanding produces a lot of dust; perform in ventilated areas such as balcony or garage.
5. 5

   Mark Shelf Board Position on Side Boards

   ≈ 20 min

   Mark the shelf board fixing position on the two side boards. Draw a horizontal line 200mm above the bottom edge of the side boards (this line represents the top surface height of the shelf board). Take the same measurement on both side boards symmetrically. Use carpenter's square and pencil to draw lines and mark pilot hole positions (center of shelf board thickness = 9mm line).

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack two side boards, mark on one, and transfer with a punch to the other to ensure exact alignment.
   • Shelf board position can be adjusted to fit equipment. Approximate height is AV amplifier height plus 50mm.
   • Pilot holes should be at center of side board thickness (18mm thickness means 9mm from edge). Misalignment causes shelf board to shift.

   Watch out

   • If left and right side boards differ in height, the shelf will tilt. Remember to transfer marking by stacking boards.
   • Pencil lines may show through after painting; draw thinly expecting to erase with eraser after assembly.
6. 6

   Drill Pilot Holes in Shelf Board and Side Boards

   ≈ 25 min

   Drill pilot holes (φ3.5mm) at the shelf board end surfaces, two locations on each side, total four holes. Also drill through side boards at marking positions with φ3.5mm drill, countersink (φ8mm×3mm deep) on the front side. Although plywood resists splitting, pilot holes near edges require caution.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersinking screw heads flush produces a neat finish.
   • Use a drill stopper to control depth and prevent drill-through; target depth is board thickness minus 2mm.
   • Clamp shelf board firmly before drilling holes at end surfaces to prevent cracking.

   Watch out

   • Driving screws closer than 10mm from edges risks splitting; keep at 9mm edge centerline.
   • Drills angled obliquely cause screw bodies to protrude on the opposite side; drill perpendicular vertically.
7. 7

   Temporary Assembly of Bottom Board and Side Boards

   ≈ 30 min

   Place bottom board on the floor and stand two side boards on top. Align bottom edges of side boards with bottom board edges. Apply a thin layer of wood glue, then drill pilot holes (φ3.5mm) from bottom board side and drive coarse-thread screws 38mm, 3 screws each side (6 total). Check right angle between side boards and bottom board using a carpenter's square while proceeding.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • The trick is applying wood glue as a thin, spread amount one toothpick wide; immediately wipe off excess with wet cloth.
   • Clamping side boards for temporary fixing before drilling keeps holes precise.
   • Ensure the floor is flat; check bottom board level with a level before assembly.

   Watch out

   • Applying too much glue causes overflow and prevents paint adhesion; thin and even application is essential.
   • Omitting pilot holes leads to plywood splitting; always pre-drill.
8. 8

   Attach Shelf Board

   ≈ 20 min

   Insert shelf board (1164mm length) according to marked position. Align ends with side boards, apply glue, drill pilot holes (φ3.5mm) from outside of side boards, and drive coarse-thread screws 38mm, 2 screws each side (total 4). Confirm shelf board levelness with a level.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf board length 1164mm = top board width 1200 minus side board thickness (18×2). Confirm measurement correctness before proceeding.
   • Shelf board is hidden inside, so countersinking holes is unnecessary.
   • If using adjustable shelf pins instead, drill multiple φ5mm holes accordingly at this step.

   Watch out

   • Shelf board too short causes wobble; too long causes side board bulging. Reconfirm cut dimensions.
   • Shelf board not level causes TV remote controls and small items to roll off; always check with a level.
9. 9

   Attach Top Board

   ≈ 25 min

   Place top board (1200mm width) on top of the box, aligning with side board top edges. Drill pilot holes (φ3.5mm) from top board side, and drive 38mm coarse-thread screws, 3 screws per side (6 total). Screw heads can be countersunk and filled later with wood dowels or putty for a neater finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • Top board is critical as TV support; increasing screws to 4 per side (8 total) improves load capacity.
   • Countersink holes filled with φ9mm wood dowels conceal joints; after painting, they become unnoticeable.
   • If TV weight is over 30kg, add a 1×2 lumber reinforcement from underneath at center of top board.

   Watch out

   • Mounting top board with grain direction reversed causes mismatched wood grain orientation; align grain before screwing.
   • For 18mm thickness board, 38mm screws are ideal; longer screws might penetrate lower shelf board.
10. 10

    Confirm Right Angles and Diagonal Measurements

    ≈ 15 min

    Check right angles of the overall cabinet by placing carpenter's square at four inside corners and confirm 90°. Measure internal diagonal lengths with tape measure and confirm both diagonals are equal (within 2mm tolerance). If distorted, loosen loose screws once, clamp to correct shape, then retighten.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • Diagonal difference over 5mm means significant distortion, causing back board not to fit; correction is mandatory.
    • Clamping the entire box diagonally helps achieve right angles easily.
    • Enlarging pilot holes to φ4mm allows some play, making adjustments easier.

    Watch out

    • Ignoring distortions at this stage causes gaps in back board corners during installation.
    • Use a reliable precision square (aluminum or steel); plastic squares have large errors.
11. 11

    Attach Back Board

    ≈ 15 min

    Place 4mm veneer (1200×1800mm) back board on the rear side and fix with tacker or small screws (φ3×20mm) along four edges and center. Use tacker with 30mm spacing or screws with 100mm spacing. The back board secures right angles, eliminating most cabinet distortions in this step.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If diagonal measurements indicated distortion before fixing back board, correct with clamps during fixation.
    • Tacker is faster; it is a tool like a thin stapler shooting fine staples.
    • Install back board grain horizontally for a neat overall appearance.

    Watch out

    • Do not attach back board upside down; color and grain differ between front and back.
    • Tacker staples might miss and protrude through back; check by hand on rear side after use.
12. 12

    Process Wiring Holes (If Needed)

    ≈ 15 min

    Drill a wiring hole in the back board using a hole saw (φ50mm) to pass TV power cord, HDMI cable, and antenna wire. Ideal position is directly behind the TV's connection terminals. If no hole saw is available, drill multiple holes and connect with a coping saw.

    Drill a hole

    φ50mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge banding tape on hole edges to protect fingers and cable covering.
    • Confirm TV terminal layout to align hole and ensure cables pass straight.
    • Align hole height with power outlet for a neater appearance.

    Watch out

    • Incorrect hole position prevent cables from emerging behind the TV, resulting in an unsightly setup. Make a mock placement and mark first.
    • Hole saw spinning freely causes plywood surface delamination; ensure center drill bit engages well.
13. 13

    Pre-paint Surface Preparation

    ≈ 15 min

    Before painting, lightly sand entire surface with #240 sandpaper, wipe dust off thoroughly with wet and dry cloths. Remove glue overflow and burrs around screw holes. For indoor use, easy-to-handle finishes such as Watco Oil, Briwax, or water-based paint are usable.

    Sand

    #240

    SandSTEP 13 / 17

    Tip

    • Always test paint on scrap material. Absorption properties differ from solid wood, potentially causing unexpected color density.
    • Water-based paint brushes wash with water and are recommended for beginners.
    • Watco Oil produces natural wood grain finish; apply by rubbing with cloth.

    Watch out

    • Glueed areas repel paint; lightly sand with #240 before painting to remove.
    • Remaining dust causes rough paint texture; thorough cleaning before painting is essential.
14. 14

    First Coat of Paint

    ≈ 30 min

    Apply paint or finish evenly over entire surface with brush or cloth. Follow order: top board → side boards → bottom board → back board. Apply along wood grain in one direction to minimize brush marks. Avoid thick coats; apply thin and uniform layers. Let dry naturally for over 2 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use small amounts of paint and close containers after use to avoid film formation.
    • If brush marks are noticeable, switch to roller brush (flat roller type) for uniform application.
    • Avoid placing painted parts near fans during drying to minimize dust and finish defects.

    Watch out

    • Thick application causes uneven drying and later peeling; thin coats applied twice is the rule.
    • Drying under direct hot airflow causes surface curing only and insufficient internal drying; natural drying is necessary.
15. 15

    Intermediate Sanding and Second Coat

    ≈ 25 min

    After first coat dries thoroughly, lightly sand surface with #320 sandpaper to remove roughness (intermediate sanding). Remove dust, then apply second coat. Apply thinner than first coat for smoother finish. Allow dry for at least 24 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Intermediate sanding only removes surface roughness without removing paint layer.
    • Thin second coats avoid drips and improve uniformity.
    • Do not touch before full drying to avoid fingerprints and dust adhesion; observe 24 hour drying time.

    Watch out

    • Excessive intermediate sanding removes first coat; use #320 lightly only.
    • Thick second coats prolong drying, delaying next day work.
16. 16

    Attach Leg Pads and Anti-tip Hardware

    ≈ 20 min

    Attach felt pads at the bottom of legs to prevent floor damage and wobbling. Install seismic belt or anti-tip hardware at upper rear for earthquake safety. Securing the TV stand to the wall with screws is the safest method to prevent tipping during major earthquakes.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads are inexpensive (~50 yen) at home centers; 10mm thickness absorbs floor unevenness.
    • Seismic belts can be found at 100-yen shops; specialized TV stand kits costing around 1000 yen offer added safety.
    • Anchor hardware to wall studs; drywall alone will not hold.

    Watch out

    • Omitting felt pads results in scratched flooring.
    • Skipping anti-tip hardware risks TV stand toppling in strong earthquakes, damaging the TV.
17. 17

    Final Inspection and Installation

    ≈ 20 min

    Move completed TV stand to installation site and check levelness front, back, left, and right with a level. Adjust any wobble with felt pads. Place TV on top, route cables, and plug in power to verify operation. Initially place only light items; wait one week for paint to fully cure before normal use.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Place TV weight evenly centered on top board to prevent deformation; placing it off-center causes warping.
    • Route cables through back board hole and bundle with zip ties for neat appearance.
    • Ensure at least 50mm ventilation space front and rear when storing AV amplifiers or BD recorders on the shelf.

    Watch out

    • Paint takes a full week to completely harden; placing objects or remote controls immediately causes stickiness.
    • Uneven floors prevent leveling; adjust felt pad thickness on each side accordingly.

Warnings

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

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