Simple TV Stand

Dimensions

Cut list

Tools you'll need

• ✓

  Tape Measure (5m or longer)

  Used for measuring each component.

• ✓

  Pencil and Carpenter's Square

  For marking layout lines and checking right angles.

• ✓

  Saw

  Home center cutting service recommended.

• ✓

  Electric Screwdriver

  Impact driver improves work efficiency.

• ✓

  Sandpaper

  Prepare grit #120 and #240.

• ✓

  Level

  Essential for checking horizontal alignment 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 the Installation Site and Confirm Fit

   ≈ 15 min

   Measure the location for the TV stand and verify that the Simple TV Stand (1200×400×400mm) fits. Also check the outlet position, wiring routes, and TV stand shape.

   Measure

   W 1200 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is TV stand width plus 100mm on each side. For wall mounting, consider reinforcing the center of the top board.
   • Select a location allowing at least 50mm of space behind for ventilation.
   • If the floor is carpeted, measure assuming a rigid board will be placed underneath to prevent leg sinking and wobble.

   Watch out

   • If the TV stand's depth (400mm) is smaller than the TV stand's base, the stand may protrude dangerously. Always measure the bottom of the TV box before purchasing.
   • If storing AV amplifiers or soundbars, confirm these fit inside the shelf internal dimensions (W1164×D390×H328mm).
2. 2

   Create Cut List and Order at Home Center

   ≈ 30 min

   Cut two pieces each of top and bottom boards (18×400×1200mm), two side boards (18×400×364mm), and one shelf board (18×390×1164mm) from 1x6 foot Lauan plywood 18mm sheets. The back panel is veneer 4mm (1200×400)×1. Because plywood sheets are heavy and large, home center cutting service is recommended.

   Cut

   Use the in-store cut service

   CutSTEP 2 / 17

   Tip

   • Home center cutting service costs about 30-50 yen per cut and can cut within ±1mm accuracy.
   • Arrange wood grain horizontally as viewed from the front for aesthetic appearance; specify grain direction when ordering.
   • Side board length 364mm accounts for double the 18mm thickness of top and bottom boards as internal dimension; communicate this length directly.

   Watch out

   • If plywood thickness differs (e.g., 12mm, 15mm, 21mm), the side board length calculation changes. Confirm actual thickness before ordering.
   • Cutting service only does straight cuts. Holes for wiring or edge chamfers must be done manually.
3. 3

   Apply Edge Band Tape

   ≈ 25 min

   Because the cut edges of plywood are rougher than the finished surfaces, apply edge band tape with an iron. Treat visible edges—the front, back, left and right edges of the top and bottom boards, as well as the front edges of side and shelf boards. Use medium iron temperature (about 150°C), pressing for 3-5 seconds.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • Edge tape adheres as its resin melts with heat. Press with a cloth before cooling to improve adhesion.
   • Trim excess tape with a utility knife by cutting gently in several passes to create a smooth finish.
   • No need to apply on back panel edges since they are not visible.

   Watch out

   • Do not move the iron continuously; hold in place for about 3 seconds before moving to the next section.
   • If the temperature is too high, the tape can burn and discolor; test temperature on leftover tape before applying.
4. 4

   Sand All Components

   ≈ 30 min

   Sand all parts lightly using #180 followed by #240 grit sandpaper. Since plywood surfaces are generally smooth, only a light pass is needed. Chamfer corners gently with #240 to avoid sharp edges. Also smooth ends of edge band tape with #240.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the wood grain to avoid raised fibers and finish inconsistency.
   • Chamfer corners so that even a tissue paper passes smoothly without catching.
   • Using a vacuum nozzle near the sander reduces dust and makes indoor work tolerable.

   Watch out

   • Plywood veneer is thin (0.2-0.5mm); aggressive sanding exposes gray underlying layer. Sand lightly.
   • Sanding generates a lot of dust; conduct work in a ventilated area like balcony or garage.
5. 5

   Mark Shelf Position on Side Boards

   ≈ 20 min

   Mark the shelf position on both side boards by drawing a horizontal line 200mm above the bottom edge (this is the shelf board top surface position). Ensure symmetrical heights on both sides. Use a carpenter’s square and pencil to draw lines and mark pilot hole positions at the center line of the side thickness (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 alignment.
   • Shelf height can be adjusted depending on device height; adding 50mm above AV amplifier height is a guide.
   • Pilot holes should be at the thickness center of side boards (9mm in) to prevent shelf misalignment.

   Watch out

   • If side boards have different heights marked, the shelf will be tilted; always transfer marks with boards stacked.
   • Pencil marks can show through after finishing; keep lines light and erase after assembly.
6. 6

   Drill Pilot Holes in Shelf Board and Side Boards

   ≈ 25 min

   Drill pilot holes (φ3.5mm) at the ends of the shelf board for attaching side boards. Drill two holes on each end (total 4). Also drill through pilot holes on the side boards at marked positions, countersink on the face side (φ8mm diameter × 3mm deep). Although plywood resists splitting, pilot holes near edges require care.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersink allows screw heads to sit flush, resulting in a neater finish.
   • Use a drill stop to control depth, roughly board thickness minus 2mm.
   • Clamp shelf board securely before drilling to prevent splitting.

   Watch out

   • Pilot holes too close (<10mm) to board edges risk splitting; keep at 9mm centerline.
   • Drilling must be perpendicular; angled holes cause screw tips to protrude through opposite side.
7. 7

   Mock Assemble Bottom Board and Side Boards

   ≈ 30 min

   Place the bottom board on the floor and stand the two side boards on top, aligning their bottom edges with the bottom board edges. Apply a thin layer of wood glue then drill pilot holes (φ3.5mm) from below and screw coarse-thread screws 38mm in three locations per side (total 6). Use a carpenter’s square to verify right angle between side boards and bottom board during assembly.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Apply glue sparingly about the width of a toothpick length, spread thinly. Wipe off excess immediately with a damp cloth.
   • Clamp side boards temporarily to avoid shift while drilling.
   • Ensure floor is level before assembly; check bottom board horizontal with a level.

   Watch out

   • Applying too much glue causes overflow that prevents paint adhesion; keep glue thin and even.
   • Never screw without pilot holes to avoid plywood cracking.
8. 8

   Attach the Shelf Board

   ≈ 20 min

   Insert the shelf board (1164mm length) at the marked height, aligning edges with side boards. Apply glue, drill pilot holes from side board outsides (φ3.5mm), and fix with two 38mm coarse-thread screws per side (total 4 screws). Confirm shelf is level with a level.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf board length 1164mm equals top board width 1200 minus double side board thickness (18mm×2). Confirm cut length before assembly.
   • Screw countersinking on shelf board is unnecessary as it is internal.
   • If using adjustable shelf pins, drill multiple φ5mm holes now.

   Watch out

   • Shelf boards too short cause wobble, too long cause side bulging; recheck measurements.
   • Non-level shelves cause TV remotes or small items to roll; use level for checking.
9. 9

   Attach the Top Board

   ≈ 25 min

   Place the top board (1200mm width) over the box, aligning with the top edges of the side boards. Drill pilot holes (φ3.5mm) from above and affix with three 38mm coarse-thread screws on each side (total 6). Countersink screw heads and fill with dowels or wood filler for a refined finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • As the most important component supporting the TV, increasing screws to four per side (total 8) improves load strength.
   • Fill countersinks with φ9mm wooden dowels to hide joints; after finishing, the joints become invisible.
   • If TV weighs over 30kg, add a 1x2 reinforcement board under the center top board.

   Watch out

   • Incorrect orientation results in wood grain mismatch; always align grain direction before screwing.
   • 38mm screws are appropriate for 18mm board thickness; longer screws risk penetrating shelf boards below.
10. 10

    Check Right Angles and Diagonal Measurements

    ≈ 15 min

    Check right angles on all four inside corners of the box using a carpenter’s square. Measure inner diagonal lengths with a tape measure; both diagonals should be equal within 2mm. If skewed, remove loosened screws and clamp to correct alignment before retightening.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • Discrepancies over 5mm indicate large distortion that prevents back panel fitting; always correct.
    • Clamping diagonally helps achieve accurate right angles.
    • Enlarging pilot holes to φ4mm creates play for easier adjustment.

    Watch out

    • Leaving skew at this stage causes large gaps when fitting back panel.
    • Use reliable high precision carpenter’s squares (aluminum or steel); plastic squares are often inaccurate.
11. 11

    Attach Back Panel

    ≈ 15 min

    Place the 4mm veneer back panel on the rear, securing to all edges and center with a staple gun or fine screws (φ3×20mm). Staple roughly every 30mm or screw every 100mm. The back panel fixes right angles and minimizes distortion.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If box is distorted from previous step, clamp while securing back panel to correct shape.
    • Stapler (tacker) is faster; it uses fine pins like a heavy-duty stapler.
    • Orient back panel grain horizontally for a neat overall look.

    Watch out

    • Avoid attaching the back panel upside down; front and back differ in color and grain.
    • Check the back after stapling for pins protruding through; smooth by hand.
12. 12

    Make Wiring Holes (If Needed)

    ≈ 15 min

    To pass power, HDMI, and antenna cables, cut a wiring hole in the back panel using a hole saw (φ50mm). Position ideally behind TV's connection ports. Without a hole saw, drill multiple holes and connect them with a fret saw.

    Drill a hole

    φ50mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge band tape around hole edges to protect fingers and cable insulation.
    • Confirm TV rear port arrangement before marking hole position.
    • Align hole height with outlet height for tidy appearance.

    Watch out

    • Wrong hole position prevents tidy cable routing; mock place TV to mark hole accurately.
    • Hole saw slipping can delaminate plywood surface; keep drill bit centered firmly.
13. 13

    Prepare Surface Before Painting

    ≈ 15 min

    Lightly sand entire unit with #240 sandpaper before painting. Remove dust thoroughly with a wet cloth then a dry cloth. Remove glue drips and screw hole burrs. Since for indoor use, Watco Oil, Briwax, or water-based paints are suitable and easy.

    Sand

    #240

    SandSTEP 13 / 17

    Tip

    • Test paint on scrap wood as plywood absorbs differently than solid wood, resulting in unexpected color intensity.
    • Water-based paints wash brushes with water and are beginner-friendly.
    • Watco Oil preserves natural wood look; apply rubbing with a cloth.

    Watch out

    • Glue spots repel paint; lightly sand those areas with #240 before painting.
    • Dust left on surface causes rough texture after painting; cleaning is critical.
14. 14

    First Coat Painting

    ≈ 30 min

    Using a brush or rag, apply paint evenly on all surfaces. Paint order: top board, side boards, bottom board, back panel. Paint along grain direction in one direction to avoid brush marks. Apply thin and even coats. Let dry naturally for over 2 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use paint in small portions to avoid skin forming in the can.
    • If brush strokes show, switch to roller brush for uniform application.
    • Dry in a dust-free environment; avoid fans blowing directly on surfaces.

    Watch out

    • Thick coats cause uneven drying and peeling later; thin two coats is best practice.
    • Drying with direct heat (e.g. heater) dries surface only causing underlayer to remain wet; allow natural drying.
15. 15

    Light Sanding and Second Coat

    ≈ 25 min

    After first coat dries completely, lightly sand surface with #320 sandpaper to remove roughness (intermediate sanding). Remove dust then apply second coat thinner than the first. Let dry at least 24 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Intermediate sanding removes surface roughness without removing the entire paint layer.
    • Apply second coat thinly to avoid runs.
    • Do not touch surface during drying to prevent fingerprints and dust marks; wait full 24 hours.

    Watch out

    • Do not sand too hard or remove first coat paint.
    • Thick second coats extend drying time and delay further work.
16. 16

    Attach Foot Pads and Earthquake Prevention Fittings

    ≈ 20 min

    Attach felt pads to leg bottoms to protect floors and reduce wobble. For earthquake safety, secure anti-tip straps or brackets to the upper rear of the unit. Fixing to the wall with screws into studs is safest.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads cost about 50 yen, 10mm thickness cushions floor unevenness better.
    • Anti-tip straps available at 100 yen shops; specialized TV stand straps (1000+ yen) offer added safety.
    • Mount wall fittings into studs; drywall alone will not hold.

    Watch out

    • Not using felt pads causes scratches on flooring.
    • Skipping earthquake prevention risks TV cabinet collapse and damage in major quakes.
17. 17

    Final Checks and Setup

    ≈ 20 min

    Move completed stand to installation spot. Verify front-to-back and side-to-side level with a level tool. Adjust wobble by varying felt pad thickness. Place TV, arrange cables through back panel hole, and test powering on. Place only light items for one week to allow full paint curing.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Center TV weight on top board to distribute load evenly; avoid off-center placement causing distortion.
    • Use cable ties to bundle wires neatly below the back panel hole for tidy appearance.
    • Leave at least 50mm ventilation clearance if AV amplifiers or Blu-ray players are stored on shelves.

    Watch out

    • Paint takes about one week to fully harden; placing controllers or devices directly on fresh paint causes stickiness.
    • Uneven floors prevent level installation; adjust felt pad thickness accordingly.

Warnings

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

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