Desk with Shelf

Dimensions

Cut list

Tools you'll need

• ✓

  Tape measure (5m or longer)

  Used for measuring each component.

• ✓

  Pencil and carpenter's square

  For marking lines and checking right angles.

• ✓

  Saw

  Use home center cutting service recommended.

• ✓

  Electric screwdriver

  Impact driver improves work efficiency.

• ✓

  Sandpaper

  Prepare two types, #120 and #240.

• ✓

  Level

  Essential for checking horizontality during assembly.

• ✓

  Clamps (2 or more)

  Used for temporary fixing during joining.

• ✓

  Brush and paint tray

  Used for oil or varnish finishing.

Materials

Build steps

1. 1

   Measure and Confirm Installation Place

   ≈ 15 min

   Measure the space where the TV stand will be installed and check if the desk with shelves (1200×600×1400mm) fits. Also check the power outlet position, wiring routes, and TV stand shape.

   Measure

   W 1200 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is the TV stand width plus 100mm on each side. Consider reinforcing the center of the top board if wall-mounted.
   • Select a place that can be set at least 50mm away from the wall to ensure front and back ventilation.
   • If the floor has carpet, measure assuming a hard board will be placed underneath since legs sink and cause wobbling.

   Watch out

   • If the TV stand depth of 600mm is too small for the TV stand base, it protrudes dangerously. Always measure the bottom surface of the TV box before purchase.
   • If storing AV amplifier or soundbar, check if device size fits inside shelf internal dimensions (W1164×D390×H328mm) beforehand.
2. 2

   Create Cut List and Order from Home Center

   ≈ 30 min

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

   Cut

   Use the in-store cut service

   CutSTEP 2 / 17

   Tip

   • Home center cutting service costs 30-50 yen per cut and offers cutting accuracy within ±1mm.
   • Grain direction looks better when horizontal from front view; specify this at ordering.
   • Side board length 364mm includes the thickness of top and bottom boards (18mm×2) in the internal dimension calculation. Communicate as is.

   Watch out

   • If plywood thickness is not 18mm (e.g. 12mm/15mm/21mm), side board length calculation changes. Confirm actual thickness before ordering.
   • Cutting service supports only straight cuts. Holes for wiring or chamfers must be made yourself.
3. 3

   Apply Edge Banding Tape

   ≈ 25 min

   Plywood cut edges are rough unlike finished surfaces, so apply edge banding tape with an iron. Treat visible edges – front, back, left, and right ends of top and bottom boards, front edge of side boards, and front edge of shelf board. Use medium heat (~150℃) with 3-5 seconds pressing.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • The tape’s resin melts and bonds with heat; pressing with a cloth while still hot improves adhesion.
   • Cut excess tape bevel-wise with a utility knife in 2-3 passes for a natural finish.
   • Back board (veneer 4mm) edges are hidden and do not require tape.

   Watch out

   • Moving iron continuously fails to heat properly; keep iron still per spot for about 3 seconds before moving.
   • Too high temperature scorches tape and alters color. Test temperature on scrap tape first.
4. 4

   Sand All Components

   ≈ 30 min

   Sand all components sequentially with #180 then #240 sandpaper. Plywood surfaces are already smooth, so just lightly sanding. Chamfer all corners lightly with #240 to avoid sharp edges. Also finish edges of edge banding tape gently with #240.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the wood grain; sanding against grain raises fibers, causing paint inconsistencies.
   • Chamfers are done when tissue paper can be softly wiped without catching.
   • Using a vacuum nozzle near the sander reduces dust by half, enabling indoor work.

   Watch out

   • Plywood face veneer is thin (0.2-0.5mm). Excessive sanding exposes the grey base layer; sand lightly only.
   • Sanding produces much dust; sand outdoors or in well-ventilated garage or balcony.
5. 5

   Mark Shelf Board Position on Side Boards

   ≈ 20 min

   Mark the shelf board mounting position on the two side boards. Draw a horizontal line 200mm up from the bottom edge of each side board (this is the shelf board top surface height). Take identical measurements on both sides to keep symmetry. Use carpenter's square and pencil to draw lines and mark pilot hole positions (at shelf board thickness midpoint, 9mm line).

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack the two side boards, mark one, then use a punch to transfer marks perfectly to the other.
   • Shelf position can be adjusted to fit devices; an allowance of AV amplifier height plus 50mm is a guide.
   • Pilot holes are at the center of side board thickness (18mm thick, so 9mm from edge). Misalignment causes shelf misplacement.

   Watch out

   • Unequal heights cause shelf tilt; don’t forget to transfer marks by stacking.
   • Pencil lines may remain visible after painting; draw lightly to erase after assembly.
6. 6

   Drill Pilot Holes on Shelf Board and Side Boards

   ≈ 25 min

   Drill pilot holes (φ3.5mm) on both ends of the shelf board, two holes per side, total four. Also drill φ3.5mm pilot holes through the marked points on the side boards, countersinking on the front side with φ8mm diameter by 3mm depth. Although plywood is resistant to splitting, pilot holes near edges need caution.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersinking screws flush results in neat finishing.
   • Use a drill stopper for depth control to prevent piercing (board thickness minus 2mm).
   • Clamp the shelf board when drilling end pilot holes to prevent cracking.

   Watch out

   • Screws punched within 10mm of edge risk splitting; maintain center line at 9mm from edge.
   • Drill perpendicularly; tilted holes cause screws to protrude on opposite side.
7. 7

   Temporary Assembly of Bottom Board and Side Boards

   ≈ 30 min

   Place bottom board on floor and stand two side boards on it. Align side board bottoms to bottom board edges, apply a thin layer of woodworking glue, then drill φ3.5mm pilot holes from bottom board side and drive three 38mm coarse-thread screws each side (six total). Use carpenter's square to check right angles between side and bottom boards during assembly.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Spread glue thinly about a toothpick's width; immediately wipe excess with damp cloth.
   • Clamp side boards temporarily to prevent movement during drilling.
   • Ensure floor is flat and check bottom board horizontality with level before assembly.

   Watch out

   • Too much glue causes overflow blocking paint adhesion; spread thin and evenly.
   • Omitting pilot holes risks plywood splitting. Always pre-drill.
8. 8

   Install Shelf Board

   ≈ 20 min

   Insert shelf board (1164mm length) aligned with the markings. Align both side board ends and shelf board edges, apply glue, drill pilot holes (φ3.5mm) through side boards, and drive two 38mm coarse-thread screws per side (total four). Confirm shelf level using a level.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf board length 1164mm equals top board width 1200mm minus side board thickness 18mm ×2; double-check dimensions before proceeding.
   • Shelf board is internal and hidden, so countersinking screw heads is unnecessary.
   • If using shelf pegs for adjustable shelves, drill multiple φ5mm holes here accordingly.

   Watch out

   • Too short shelf causes wobble; too long pushes side boards outward. Confirm cutting dimensions.
   • Uneven shelf causes remote controls and small items to roll off; always check level.
9. 9

   Install Top Board

   ≈ 25 min

   Place top board (1200mm wide) on assembled box aligning with side board upper edges. Drill φ3.5mm pilot holes from top board side and drive six 38mm coarse-thread screws (three per side). Hide screw heads in countersink holes and fill with wooden dowels or wood putty for a neat finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • Top board bears TV weight; increasing screw count to eight (four per side) improves load capacity.
   • Fill countersink holes with φ9mm wooden dowels, which become inconspicuous after painting.
   • For TVs heavier than 30kg, reinforce underside center of top board with an additional 1×2 lumber.

   Watch out

   • Installing top board reversed causes misaligned grain direction; align grain before securing.
   • 38mm screw length suits 18mm top board; longer screws risk penetrating shelf board below.
10. 10

    Check Right Angles and Diagonal Lengths

    ≈ 15 min

    Confirm overall box right angles. Place carpenter's square at four interior corners and check 90°. Measure internal diagonal lengths with tape measure to ensure they are equal within 2mm tolerance. If misaligned, loosen a screw, clamp to correct shape, then retighten.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • Diagonal differences over 5mm indicate significant distortion; correct to fit back board properly.
    • Clamping box diagonally helps achieving right angles.
    • Enlarging pilot holes to φ4mm creates slight play facilitating adjustments.

    Watch out

    • Ignoring distortion will cause gaps fitting the back board.
    • Use reliable metal carpenter's square; plastic ones have large errors.
11. 11

    Attach Back Board

    ≈ 15 min

    Place 4mm veneer back board against the rear, fixing it with a stapler or thin screws (φ3×20mm) around edges and center. Staple spacing about 30mm, screw spacing about 100mm. The back board stabilizes the box and corrects distortion in this step.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If distortion remains after diagonal check, clamp box while fixing back board.
    • Stapler is faster; it drives thin pins like a large stapler.
    • Install wood grain horizontally for a neat appearance of TV stand.

    Watch out

    • Ensure correct orientation; front and back have different color and grain.
    • Staple pins occasionally miss and protrude inside; check back surface by hand after work.
12. 12

    Make Cable Holes (If Needed)

    ≈ 15 min

    Use a hole saw (φ50mm) to drill cable holes in the back board for TV power cords, HDMI, and antenna cables. Ideally place holes directly behind TV connection terminals. If no hole saw, drill multiple holes and connect with a fret saw.

    Drill a hole

    φ50mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge banding tape on hole edges to protect fingers and cable jackets.
    • Check TV rear connector layout to locate holes for straight cable routing.
    • Align hole height with power outlet for a clean look.

    Watch out

    • Incorrect hole placement causes cables to exit improperly behind TV leading to unsightly wiring.
    • Hole saw slipping causes plywood surface peeling; ensure drill bit center is secure.
13. 13

    Prepare Surface Before Painting

    ≈ 15 min

    Lightly sand entire surface with #240 sandpaper before painting. Remove dust thoroughly with damp cloth and dry cloth. Remove excess woodworking glue and burrs near screw holes. Suitable finishes include Watco Oil, Briwax, or water-based paints for indoor use.

    Sand

    #240

    SandSTEP 13 / 17

    Tip

    • Always test paint on scrap to check color as plywood absorbs differently than solid wood.
    • Water-based paints are easy to clean with water and recommended for beginners.
    • Watco Oil yields a natural finish preserving wood feel; apply by rubbing in with cloth.

    Watch out

    • Glue spots repel paint; lightly sand glue areas before painting.
    • Failing to remove dust causes rough texture; clean thoroughly before painting.
14. 14

    First Coat of Paint

    ≈ 30 min

    Apply paint evenly over entire surface using brush or rag. Coat in order: top board, side boards, bottom board, then back board, brushing from larger to smaller surfaces. Paint along wood grain in one direction to avoid brush marks. Apply thin coats, let dry naturally for over 2 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use small portions to prevent paint drying out; do not leave can open.
    • For less brush marks, use a foam roller brush for even coating.
    • Dry in dust-free area; avoid fan airflow that causes blowing dust.

    Watch out

    • Thick coats cause uneven drying and peeling later; thin multiple coats are essential.
    • Drying under direct heating causes surface drying only; natural air drying required.
15. 15

    Intermediate Sanding and Second Coat

    ≈ 25 min

    After first coat dries completely, lightly sand surface with #320 sandpaper (intermediate sanding) to smooth roughness. Remove dust then apply second coat thinner than first for even finish. Let dry for 24 hours or more.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Intermediate sanding should only smooth surface imperfections, not remove paint.
    • Apply second coat thinly; thick coats cause dripping.
    • Avoid touching surface during drying to prevent fingerprints and dust. Maintain 24-hour drying time.

    Watch out

    • Sanding too aggressively removes first coat; light sanding with #320 is key.
    • Thick second coats increase drying time, delaying next steps.
16. 16

    Attach Furniture Pads and Anti-Tip Hardware

    ≈ 20 min

    Stick felt pads on the bottom of legs to prevent floor scratches and wobbling. For earthquake safety, install anti-tip brackets or straps at upper backside to fix TV stand securely to wall with screws. Fixing to wall studs provides maximum safety.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads cost about 50 yen at hardware stores; 10mm thickness absorbs floor unevenness well.
    • Anti-tip straps available at 100-yen shops; specialized products costing 1000 yen+ provide better safety.
    • Attach brackets to wall studs; single-layer drywall won't hold securely.

    Watch out

    • Skipping felt pads causes scratches on flooring.
    • Not installing anti-tip hardware risks TV stand toppling in major earthquakes and TV damage.
17. 17

    Final Check and Installation

    ≈ 20 min

    Move completed TV stand to installation site. Use a level to confirm front-to-back and left-to-right horizontality. Adjust wobbling by placing felt pads. Place TV, run cables and power on to check operation. Use light load for first day and wait one week for paint to fully cure.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Place TV centered on top board to distribute weight evenly; placing off-center causes deformation.
    • Route cables through back board holes and bundle with zip ties for neat appearance.
    • Allow 50mm ventilation space front and back if putting AV amplifier or Blu-ray player on shelf.

    Watch out

    • Full paint cure takes one week; placing remote or equipment directly on freshly painted surface causes stickiness.
    • Uneven floors may prevent leveling; adjust felt pad thickness on each side accordingly.

Warnings

• ⚠️Drill pilot holes before screwing to prevent wood splitting.

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