Lowboard with Storage

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring tape (at least 5m)

  Used for measuring each component.

• ✓

  Pencil and carpenter's square

  Used for marking lines and checking right angles.

• ✓

  Saw

  Recommended to use home center cutting service.

• ✓

  Electric screwdriver

  Impact driver improves work efficiency.

• ✓

  Sandpaper

  Prepare #120 and #240 types.

• ✓

  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

   Measuring and Confirming Installation Location

   ≈ 15 min

   Measure the placement area for the TV stand and check if the storage lowboard (1800×450×450mm) fits. Also verify outlet positions, wiring routes, and TV stand shape.

   Measure

   W 1800 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal clearance is TV stand width plus 100mm on each side. Consider reinforcing the center of the top board if wall-mounted.
   • Choose a location allowing at least 50mm clearance from the wall for ventilation front and back.
   • If the floor is carpeted, measure assuming a hard board will be placed underneath to prevent legs sinking and wobbling.

   Watch out

   • If the TV stand's depth (450mm) is less than the TV stand base, the front may protrude dangerously. Measure the base of the TV box before purchase.
   • If storing AV amps or soundbars, confirm device sizes fit within the shelf's inner dimensions (W1164×D390×H328mm) beforehand.
2. 2

   Creating Cut List and Ordering at Home Center

   ≈ 30 min

   Cut from 18mm luan plywood 1×6 boards: top and bottom boards (18×400×1200)×2, side boards (18×400×364)×2, shelf board (18×390×1164)×1. Back panel is veneer 4mm (1200×400)×1. Due to large size and weight, using 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 can cut within ±1mm accuracy.
   • For aesthetic wood grain appearance, specify horizontal grain when viewed from front.
   • Side board length 364mm includes thickness of top and bottom boards (18mm each); communicate this dimension as is.

   Watch out

   • If plywood thickness differs (12mm, 15mm, 21mm, etc.), side board length calculations change. Confirm actual thickness before ordering.
   • Cutting service only performs straight cuts; wiring holes or chamfering must be done separately.
3. 3

   Applying Edge Banding Tape

   ≈ 25 min

   The cut edges of plywood are rough compared to finished surfaces. Apply edge banding tape with an iron on visible edges: all sides of top and bottom boards, front edges of side boards and shelf board. Use medium heat (~150°C), pressing for 3-5 seconds.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • The tape adheres as resin melts with heat; pressing with cloth before cooling improves adhesion.
   • Trim excess tape with a cutter at slight angles in 2-3 stages for natural finish.
   • No need to apply tape on back panel (4mm veneer) edges as they are not visible.

   Watch out

   • Do not move iron continuously; hold still for 3 seconds per spot before moving on.
   • Excessive heat will burn the tape and change color; test temperature on leftover tape first.
4. 4

   Sanding All Components

   ≈ 30 min

   Sand all components starting with #180 grit then #240 grit sandpaper. Lightly smooth plywood surfaces. Use #240 to gently chamfer corners to prevent sharpness. Also, softly finish edges of the edge banding tape.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the grain to avoid raising fiber and paint unevenness.
   • Corners should be smooth enough to feel no snagging even when gently brushed with tissue paper.
   • Use a vacuum close to the sander to reduce dust, suitable for indoor work.

   Watch out

   • Plywood veneer layer is thin (0.2-0.5mm); excessive sanding exposes the gray substrate. Sand lightly only.
   • Sanding produces large amounts of dust; perform in well-ventilated areas such as balconies or garages.
5. 5

   Marking Shelf Position on Side Boards

   ≈ 20 min

   Mark the shelf fixing position on the two side boards. Draw a horizontal line 200mm up from the bottom edge (this is the shelf top surface position). Ensure symmetry on both sides. Use carpenter’s square and pencil to draw lines and mark pilot hole positions on shelf thickness center line (9mm from edge).

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack side boards and mark one; transfer marks to the other using a punch for perfect match.
   • Adjust shelf height to fit devices; target approx. AV amp height plus 50mm clearance.
   • Pilot holes are located at center of 18mm side board thickness (9mm); deviation causes shelf misalignment.

   Watch out

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

   Drilling Pilot Holes on Shelf Board and Side Boards

   ≈ 25 min

   Drill four φ3.5mm pilot holes on shelf board ends for side board fixing (2 on each end). Through holes (φ3.5mm) with countersink (φ8mm × 3mm depth) are drilled on side boards at marked positions. Though plywood resists splitting, caution near edges is needed.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersinking allows screw heads to sit flush for better finish.
   • Use drill depth stop to prevent drills going through improperly; aim for board thickness minus 2mm.
   • Clamp boards firmly before drilling shelf end holes to avoid splitting.

   Watch out

   • Screws closer than 10mm from edges risk splitting; keep on centerline 9mm from edge.
   • Drill perpendicularly to avoid screws protruding on opposite side.
7. 7

   Temporary Assembly of Bottom and Side Boards

   ≈ 30 min

   Place bottom board on floor, stand side boards on it aligning their bottom edges. Apply a thin layer of wood glue, then drill φ3.5mm pilot holes from bottom board side and drive three 38mm coarse-thread screws per side (6 total). Use square to ensure right angles between bottom and sides.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Spread glue thinly about the thickness of a toothpick; wipe off excess immediately with damp cloth.
   • Clamp side boards during pilot hole drilling to prevent shift.
   • Ensure floor is flat and bottom board horizontal with level before assembling.

   Watch out

   • Excess glue oozing out prevents smooth painting; glue should be thin and even.
   • Driving screws without pilot holes causes plywood splitting; always drill pilot holes first.
8. 8

   Installing Shelf Board

   ≈ 20 min

   Insert the shelf board (1164mm length) at marked height between side boards. Align ends squarely, apply wood glue, drill φ3.5mm pilot holes from outside of side boards, and insert two 38mm coarse-thread screws per side (4 total). Use level to confirm shelf is horizontal.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Check the 1164mm length equals (top board width 1800mm minus 2×18mm side board thickness) before proceeding.
   • Shelf is inside the box and concealed; countersinking screw holes is unnecessary here.
   • For adjustable shelves with shelf pins, drill multiple φ5mm holes at this step accordingly.

   Watch out

   • Shelf board too short causes wobble; too long causes side boards to bulge out. Reconfirm cut dimensions.
   • Uneven shelf causes TV remote controls or small items to roll; always confirm horizontality with level.
9. 9

   Attaching Top Board

   ≈ 25 min

   Place the top board (1200mm width) on the box, aligning its edges with side boards tops. Drill φ3.5mm pilot holes from top board side and insert three 38mm coarse-thread screws per side (6 total). Screw heads sit in countersink holes; filler with wooden dowels or wood putty for cleaner finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • Top board supports the TV; increasing screws to four per side (8 total) increases load capacity.
   • Filling countersink holes with φ9mm wooden dowels makes seams disappear after painting.
   • For very heavy TVs (over 30kg), add reinforcement by attaching a 1×2 lumber under the center from backside.

   Watch out

   • Reversing front and back of top board causes mismatched grain direction; align grain before screwing.
   • 38mm screws fit perfectly for 18mm thick top board; longer screws risk penetrating through shelf board below.
10. 10

    Right Angle and Diagonal Check

    ≈ 15 min

    Verify overall box right angles by placing a square on all four inside corners ensuring 90 degrees. Measure inner diagonal lengths with tape measure to confirm both diagonals are equal within 2mm. If misaligned, loosen screws, clamp to correct, then retighten.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • A diagonal difference over 5mm indicates large distortion that will prevent back panel fitting; correction is mandatory.
    • Clamping the box diagonally helps achieve right angles.
    • Widening pilot holes to φ4mm provides play allowing easier adjustment.

    Watch out

    • Ignoring distortion at this stage causes big gaps when fitting back panel.
    • Use reliable squares made of aluminum or steel; plastic squares have large errors.
11. 11

    Attaching Back Panel

    ≈ 15 min

    Place 4mm veneer back panel (1800×450mm) on the rear inside, fix edges and center with staples or fine screws (φ3×20mm). Staples every 30mm or screws every 100mm spacing. Back panel secures right angles, eliminating most box distortion.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If the box was distorted, clamp for correction when fixing back panel.
    • Staplers operate fast and use thin staples similar to large staples.
    • Orient back panel grain horizontally for a neat overall TV stand look.

    Watch out

    • Do not attach back panel reversed; front and back differ in color/grain.
    • Check backside for protruding staples which can catch; smooth with hand after work.
12. 12

    Processing Wiring Hole (If Necessary)

    ≈ 15 min

    Drill a wiring hole in the back panel for TV power cords, HDMI cables, and antenna cables using a 50mm hole saw. Position ideally behind TV connection terminals. If hole saw is unavailable, drill multiple holes and connect with a jigsaw.

    Drill a hole

    下穴 φ3.5mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge banding tape to hole edge to protect fingers and cable insulation.
    • Confirm TV rear terminal layout to position hole for straight cable routing.
    • Align hole height with power outlet for neat appearance.

    Watch out

    • Incorrect hole position forces cables to exit uncomfortably behind TV; mark after mock TV placement.
    • Hole saw slipping damages plywood surface; ensure drill bit is firmly engaged at center.
13. 13

    Preparing Surface for Painting

    ≈ 15 min

    Lightly sand entire assembly with #240 sandpaper before painting. Remove all dust thoroughly with damp rag and dry cloth. Remove glue overflow and burrs around screw holes. Suitable finishes include Watco Oil, Briwax, or water-based paint for indoor use.

    Sand

    #240

    SandSTEP 13 / 17

    Tip

    • Always test paint on scrap to check absorption; plywood behaves differently than solid wood regarding color depth.
    • Water-based paints rinse brushes with water, recommended for beginners.
    • Watco Oil leaves natural wood touch by rubbing on with cloth.

    Watch out

    • Glue spots repel paint; sand those areas lightly with #240 beforehand.
    • Painting over dust results in rough surface; thoroughly clean before painting.
14. 14

    First Coat Painting

    ≈ 30 min

    Apply paint or finish evenly with brush or cloth, starting from top board to side boards, bottom board, and back panel, going from larger to smaller surfaces. Apply along grain in one direction to avoid brush marks. Apply thin, uniform coats and allow 2+ hours to dry naturally.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use small paint portions and keep cans closed to avoid film formation that ruins remaining paint.
    • If brush strokes are visible, switch to foam roller brush for uniform application.
    • Place in low-dust area for drying; avoid direct fan airflow.

    Watch out

    • Thick coats cause uneven drying and later peeling; apply thin layers in two coats.
    • Direct heat causes surface drying only and leaves underlying moisture; always allow natural drying.
15. 15

    Intermediate Sanding and Second Coat

    ≈ 25 min

    After first coat fully dries, lightly sand surface with #320 sandpaper removing roughness. Clean dust and apply second coat thinner than first, resulting in a smoother finish. Allow at least 24 hours drying.

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Do not sand off entire first coat; just smooth surface roughness.
    • Second coat must be thin to avoid drips.
    • Do not touch surface before drying 24 hours to prevent fingerprints and dust adhesion.

    Watch out

    • Excessive sanding removes first coat.
    • Thick second coat extends drying, delaying next steps.
16. 16

    Attaching Leg Pads and Anti-Tip Hardware

    ≈ 20 min

    Attach felt pads to leg bottoms to prevent floor scratches and wobbling. For earthquake safety, install anti-tip belts or brackets near upper back, fixing to the wall securely. Fixing to wall studs with screws is safest.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads available at home centers for about 50 yen; 10mm thickness absorbs floor unevenness.
    • Anti-tip belts can be found at 100-yen shops; dedicated TV stand straps costing ~1000 yen offer better security.
    • Wall fastening must align with wall studs; drywall alone does not hold screws securely.

    Watch out

    • Skipping felt pads causes floor damage.
    • Omitting anti-tip hardware risks TV stand overturning during major earthquakes.
17. 17

    Final Check and Installation

    ≈ 20 min

    Move completed TV stand to placement area. Use level to verify front-back and side-to-side horizontality; adjust felt pads for wobble. Place TV, route cables, power on and confirm operation. Load only light items on first day; wait about one week for paint to fully cure before regular use.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Center the TV weight evenly on top board to avoid warping.
    • Route cables through back panel holes and bundle with cable ties for neatness.
    • Maintain 50mm front and back ventilation space if placing AV amps or BD recorders on shelves.

    Watch out

    • Paint takes about one week to fully cure; avoid placing remotes or equipment directly immediately.
    • Uneven floors cause leveling difficulties; adjust felt pad thickness on each side accordingly.

Warnings

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

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