Kitchen Workbench

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring Tape (5m or longer)

  Used for measuring all parts

• ✓

  Pencil and Carpenter's Square

  For marking lines and confirming right angles

• ✓

  Saw

  Home center cutting service recommended

• ✓

  Electric Driver

  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 Location

   ≈ 15 min

   Measure the location intended for the TV stand and ensure the kitchen workbench (900×600×850mm) fits. Check outlet positions, wiring paths, and the TV stand shape.

   Measure

   W 900 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is the TV stand width plus 100mm on each side. If wall-mounted, consider reinforcement at the center of the top board.
   • Select a spot with at least 50mm clearance from the wall front-to-back for ventilation.
   • If placing on carpet, measure assuming a hard board underneath to prevent leg sinking and wobbling.

   Watch out

   • If the TV stand's depth of 600mm is smaller than the TV stand width, the TV may protrude dangerously. Always measure the TV box bottom before purchase.
   • If storing AV amplifier or soundbar, confirm if they fit inside shelf dimensions (W1164×D390×H328mm).
2. 2

   Create Cut List and Order from Home Center

   ≈ 30 min

   From 1×6-foot Lauan plywood 18mm, cut: top and bottom boards (18×400×1200)×2, side boards (18×400×364)×2, shelf board (18×390×1164)×1. Back panel from 4mm plywood (1200×400)×1. The plywood is heavy and large; use the home center's cutting service.

   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.
   • Orient wood grain horizontally when viewed from the front; specify this when ordering.
   • The side board length 364mm accounts for the thickness of top and bottom boards (18mm×2) for internal dimension; transmit this length as is.

   Watch out

   • If plywood thickness is not 18mm (e.g., 12mm/15mm/21mm), side board length calculations change. Verify actual thickness before ordering.
   • Cutting service only offers straight cuts; drilling holes or chamfering must be done by yourself.
3. 3

   Apply Edge Banding Tape

   ≈ 25 min

   Plywood cut edges are rough compared to finished surfaces. Apply edge banding tape with an iron to visible edges — front, back, left, and right edges of top and bottom boards, front edges of side boards and shelf board. Iron at medium temperature (~150℃) for 3-5 seconds per spot.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • Edge banding tape melts its resin with heat to adhere; pressing with a cloth before cooling improves adhesion.
   • Trim excess tape edges carefully with a cutter in 2-3 passes for a natural finish.
   • No need to apply edge tape to back panel edges as they are not visible.

   Watch out

   • Moving the iron while applying heat prevents adhesion; pause 3 seconds per spot before moving.
   • Too high temperature burns the tape and discolors it; test on leftover tape first.
4. 4

   Sand All Components

   ≈ 30 min

   Sand all parts sequentially with #180 then #240 sandpaper. Plywood surfaces are originally smooth; a light touch suffices. Lightly chamfer corners with #240 sandpaper to avoid sharp edges. Gently finish tape edges with #240 as well.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand with the wood grain; sanding against it raises fibers causing uneven paint later.
   • Chamfer corners until you can smoothly brush tissue paper without catching.
   • Using a vacuum nozzle near the sander reduces dust by half, making indoor work bearable.

   Watch out

   • Plywood veneer is thin (0.2-0.5mm); excessive sanding exposes the gray base layer. Sand lightly only.
   • Sanding produces large dust quantities; perform in ventilated areas like balconies or garages.
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 up from the bottom edge (this is the shelf board top surface height). Ensure symmetry left and right. Use carpenter's square and pencil to draw lines and mark pilot hole position at shelf board thickness midpoint (9mm from edge).

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack side boards and mark one, then transfer marks to the other using a center punch for perfect alignment.
   • Shelf height can be adjusted to fit equipment; add about 50mm above AV amplifier height.
   • Pilot holes are at the side board thickness center (9mm from edge); deviations cause shelf misalignment.

   Watch out

   • Mismatched heights between side boards make shelves tilt; always transfer marks by stacking.
   • Pencil lines may show through paint; draw lightly and plan to erase after assembly.
6. 6

   Drill Pilot Holes in Shelf Board and Side Boards

   ≈ 25 min

   Drill pilot holes (φ3.5mm) at both ends of the shelf board (total 4 holes) for fixing to side boards. Also drill through side board mark positions with φ3.5mm drill; countersink on the front side φ8mm×3mm deep. Plywood resists splitting but be cautious near edges.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersink screw heads to be flush for a clean finish.
   • Use a drill depth stop to prevent over-penetration; set ~2mm less than board thickness.
   • Clamp parts firmly before drilling pilot holes to prevent splitting, especially near edges.

   Watch out

   • Screws placed within 10mm from edges risk splitting; keep pilot hole line at 9mm.
   • Drill perpendicular to avoid screw protrusion on opposite side.
7. 7

   Temporary Assembly of Bottom Board and Side Boards

   ≈ 30 min

   Place the bottom board on the floor and stand the two side boards on top. Align side boards bottom edges to bottom board edges. Spread wood glue thinly, then drill φ3.5mm pilot holes from bottom board side and fasten with 3 coarse-thread 38mm screws per side (total 6). Confirm right angles between parts using a carpenter's square while assembling.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Apply glue thinly, about the thickness of a toothpick, spread evenly. Wipe excess immediately with a wet cloth.
   • Clamp side boards before drilling to avoid movement.
   • Ensure the floor is level to prevent distorted assembly; verify bottom board level with a level.

   Watch out

   • Excessive glue may seep and prevent paint adhesion; apply thinly.
   • Driving screws without pilot holes causes plywood splitting; always pre-drill.
8. 8

   Attach Shelf Board

   ≈ 20 min

   Insert shelf board (1164mm length) at marked position. Align shelf and side board ends. Spread glue, drill φ3.5mm pilot holes from the side board exterior, and drive 2 coarse-thread 38mm screws per side (total 4). Confirm shelf board level with a level.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf length 1164mm = top board width 900mm minus double side board thickness 18mm×2; verify this measurement before proceeding.
   • No countersinking needed for hidden shelf screw holes.
   • To make the shelf adjustable, drill multiple φ5mm holes now for shelf pins.

   Watch out

   • A shelf that's too short wobbles; too long causes side boards to bow outward. Double-check cut sizes.
   • Uneven shelf leveling causes small items or remotes to roll off. Always confirm level.
9. 9

   Attach Top Board

   ≈ 25 min

   Place the top board (1200mm width) atop the frame, aligning with the side boards' top edges. Drill φ3.5mm pilot holes from top and drive 3 coarse-thread 38mm screws per side (total 6). Screw heads should be countersunk and later covered with wooden dowels or wood filler for a refined finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • The top board supports the TV; more screws (4 per side, total 8) improve load capacity.
   • Fill countersunk holes with φ9mm wood dowels for seamless joints after painting.
   • For very heavy TVs (>30kg), add reinforcement such as 1×2 lumber beneath the center top board.

   Watch out

   • Installing the top board with the grain reversed results in mismatched directions; align grain before fastening.
   • 38mm screws suit 18mm board thickness; longer screws risk penetrating shelf board underneath.
10. 10

    Check Right Angles and Diagonals

    ≈ 15 min

    Confirm right angles of the assembled frame with a carpenter's square at all four inner corners. Measure diagonal lengths inside with a tape measure, ensuring both diagonals are equal within 2mm. If misaligned, loosen screws, correct using clamps, then re-tighten.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • If diagonal difference exceeds 5mm, distortion is significant; correct before back panel installation.
    • Clamping the entire frame diagonally helps achieve right angles.
    • Enlarging pilot holes to φ4mm gives slight play for easier adjustment.

    Watch out

    • Ignoring frame distortions now leads to large gaps when fitting back panel.
    • Use reliable precision squares (aluminum or steel); plastic ones have large errors.
11. 11

    Attach Back Panel

    ≈ 15 min

    Place the 4mm plywood back panel (900×850mm) on the rear and fasten its four edges and center with staples or fine screws (φ3×20mm). Staple spacing should be ~30mm; screws ~100mm. The back panel secures right angles and nearly eliminates distortion at this step.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If distorted, correct with clamps during fastening using diagonal measurements.
    • Staplers work faster; they shoot thin staples like oversized staples.
    • Arrange plywood grain horizontally for a neat overall appearance.

    Watch out

    • Avoid attaching back panel reversed; colors and grain differ on each side.
    • Missed staples can protrude; feel the back side carefully after fastening.
12. 12

    Make Wiring Hole (If Needed)

    ≈ 15 min

    Drill cable holes (φ50mm) in the back panel for TV power, HDMI, and antenna cables. Position holes directly behind TV connection terminals. Without a hole saw, drill multiple holes and connect with a fret saw straightforwardly.

    Drill a hole

    φ50mm

    DrillSTEP 12 / 17

    Tip

    • Attach edge banding tape around holes to avoid finger cuts and protect cable jackets.
    • Confirm terminal layout of TV before positioning to ensure straight cable routing.
    • Match hole height with power outlet for a tidy appearance.

    Watch out

    • Incorrect hole position prevents cables from exiting behind TV neatly.
    • Hole saw spinning freely peels off plywood veneer; keep drill bit centered firmly.
13. 13

    Prepare Surface for Painting

    ≈ 15 min

    Lightly sand entire assembled unit with #240 sandpaper before painting. Remove all dust with a damp cloth followed by a dry cloth. Remove any wood glue overflow and burrs around 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 a scrap piece; plywood absorbs differently than solid wood, affecting color intensity.
    • Water-based paint allows brush washing with water; recommended for beginners.
    • Watco Oil produces a natural finish preserving wood surface; apply with cloth by rubbing in.

    Watch out

    • Glue spots repel paint; lightly sand these areas before painting.
    • Painting over dust causes rough surfaces; thoroughly clean before applying paint.
14. 14

    First Coat of Paint

    ≈ 30 min

    Apply paint across all surfaces with brush or rag in sequence: top board, side boards, bottom board, back panel. Brush along wood grain in one direction to avoid brush marks. Apply thin, even coats without buildup. Let dry naturally for at least 2 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use paint in small amounts; leave can open leads to skin forming making it unusable.
    • If brush marks are visible, use a foam roller to apply paint evenly on flat surfaces.
    • Keep painted parts in dust-free place; avoid fans blowing directly on wet paint.

    Watch out

    • Thick coats cause uneven drying leading to peeling later; apply two thin coats instead.
    • Drying near direct heat dries surface only, leaving beneath wet; always allow natural curing.
15. 15

    Sand Between Coats and Apply Second Coat

    ≈ 25 min

    Once first coat dries fully, sand surface lightly with #320 sandpaper to remove roughness. Remove dust then apply second coat thinner than first for even finish. Let dry at least 24 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Avoid sanding through paint; just even out surface roughness.
    • Apply second coat thinly to avoid drips.
    • Do not touch during drying; 24 hour curing time is necessary.

    Watch out

    • Excessive sanding removes first coat paint; keep light with #320.
    • Heavy second coat prolongs drying and delays next steps.
16. 16

    Attach Leg Pads and Anti-Tip Fittings

    ≈ 20 min

    Attach felt pads to leg bottoms to protect floor and prevent wobble. For earthquake safety, install anti-tip brackets or straps near the top back and secure to wall studs with screws.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads cost about 50 yen each at home centers; 10mm thickness absorbs floor irregularities better.
    • Anti-tip straps available at 100-yen stores; dedicated furniture straps cost about 1000 yen and provide better security.
    • Secure to wall studs; drywall alone won't hold screws effectively.

    Watch out

    • Skipping felt pads results in scratched flooring.
    • Without anti-tip measures, the TV stand may fall and damage the TV during large earthquakes.
17. 17

    Final Check and Installation

    ≈ 20 min

    Move completed TV stand to location. Check front-back and left-right level with a level. Adjust wobble with felt pads. Place TV, route cables, and confirm power on and operation. For the first day, place only light objects; wait one week for paint to fully cure.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Place TV centered for even weight distribution to avoid warping, not near edges.
    • Route cables through back panel holes and group neatly with cable ties for tidiness.
    • Allow at least 50mm front and back ventilation space for AV amplifiers and Blu-ray players in shelves.

    Watch out

    • Paint requires one week to fully harden; placing remotes or devices directly on fresh paint causes stickiness.
    • Uneven floors require varying felt pad thicknesses left to right to level the stand.

Warnings

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

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