Corner TV Stand

Dimensions

Cut list

Tools you'll need

• ✓

  Tape measure (5 m or longer)

  Used for measuring all parts

• ✓

  Pencil and carpenter's square

  For marking and checking right angles

• ✓

  Saw

  Home center cutting service recommended

• ✓

  Electric screwdriver

  Impact driver improves work efficiency

• ✓

  Sandpaper

  Prepare types #120 and #240

• ✓

  Level

  Essential for checking horizontality during assembly

• ✓

  Clamps (2 or more)

  Used for temporary fixation during joining

• ✓

  Brush and paint tray

  Used for applying oil or varnish finish

Materials

Build steps

1. 1

   Measuring and checking installation location

   ≈ 15 min

   Measure the installation location of the TV stand and confirm that the corner TV stand (900×900×450mm) fits. Check outlet positions, wiring routes, and TV stand shape.

   Measure

   W 900 mm

   MeasureSTEP 1 / 17

   Tip

   • Ideal to allow 100mm clearance on each side plus the width of the TV stand.
   • Choose a location allowing at least 50mm clearance from the wall for front-back ventilation.
   • If the floor is carpeted, measure assuming placing a hard board under the legs to prevent wobbling.

   Watch out

   • If the TV stand depth (900mm) is smaller than the TV stand base, the TV may protrude dangerously. Always measure the bottom surface of the TV box before purchase.
   • If storing AV amp or soundbar, confirm device size fits inside shelf internal dimensions (W1164×D390×H328mm).
2. 2

   Creating a cut list and ordering from home center

   ≈ 30 min

   Cut the following from 18mm lauan 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 4mm veneer (1200×400)×1. Home center cutting service is recommended due to large size and weight.

   Cut

   Use the in-store cut service

   CutSTEP 2 / 17

   Tip

   • Cutting service costs about 30-50 yen per cut with accuracy within ±1mm.
   • Grain direction is horizontally aesthetic from front, specify when ordering.
   • Side board length 364mm includes thickness of top/bottom boards (18mm×2), so order as is.

   Watch out

   • If purchased plywood thickness differs from 18mm (e.g. 12mm/15mm/21mm), recalculate side board length.
   • Cutting service is limited to straight cuts; holes and chamfers must be processed by yourself.
3. 3

   Applying edge banding tape

   ≈ 25 min

   Edge tape is ironed onto the cut edges of plywood, which are rough compared to finished surfaces. Treat visible edges on the top/bottom boards (all sides), front edges of side boards, and front edge of shelf board. Use medium heat (about 150°C) for 3-5 seconds per spot.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 17

   Tip

   • Edge tape bonds with heat-melted resin; pressing with cloth while warm enhances adhesion.
   • Trim excess tape carefully with a knife in small strokes for a natural finish.
   • No need to apply edge tape on back panel edges as they are not visible.

   Watch out

   • Do not move iron continuously to ensure heat penetration; hold still for 3 seconds then move.
   • High heat burns tape causing color change; test temperature on leftover tape first.
4. 4

   Sanding all parts

   ≈ 30 min

   Sand all parts in order #180 then #240 grit sandpaper. Since plywood surface is already smooth, light sanding is sufficient. Use #240 grit to gently chamfer edges to prevent injury. Also sand edges of edge banding tape gently with #240.

   Sand

   #180

   SandSTEP 4 / 17

   Tip

   • Sand along the grain to prevent raising fibers and uneven finish.
   • Chamfer edges so that a tissue paper glides smoothly without snagging.
   • Use a sander near a vacuum nozzle to reduce dust when working indoors.

   Watch out

   • Plywood veneer is thin (0.2-0.5mm); sanding aggressively exposes underlying gray layer. Sand lightly.
   • Sanding produces lots of dust; do sanding in ventilated area such as balcony or garage.
5. 5

   Marking shelf position on side boards

   ≈ 20 min

   Mark the position of the shelf board on the two side boards. Draw a horizontal line 200mm from the bottom edge; this indicates the top surface of the shelf board. Ensure symmetrical height on both sides. Mark pilot hole positions centered thick-wise (9mm from edge) with pencil and carpenter's square.

   Mark a line

   Use a try square

   MarkSTEP 5 / 17

   Tip

   • Stack both side boards and mark one; transfer mark by tapping with a punch on the other for perfect alignment.
   • Shelf height can be adjusted as needed; 50mm above AV amp height is standard.
   • Pilot holes located at side board thickness center (9mm from edge); misalignment causes shelf to sit crooked.

   Watch out

   • Height differences between side boards cause shelf tilt; remember to transfer marks precisely.
   • Pencil marks can show through paint; draw lightly 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 edges (two each side) for fastening to side boards. Drill φ3.5mm through pilot holes on side board markings with countersinks (φ8mm×3mm deep) on front side. Although plywood resists splitting, be cautious near edges.

   Drill a hole

   φ3.5mm

   DrillSTEP 6 / 17

   Tip

   • Countersinks allow screw heads to sit flush, creating a neat finish.
   • Use drill stopper to control depth to about 2mm less than thickness to prevent overdrilling.
   • Clamp parts firmly to avoid splitting, especially when drilling holes near edges.

   Watch out

   • Do not place screws within 10mm to the edge to avoid splitting; maintain the 9mm centerline rule.
   • Drill vertically; angled 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, stand the two side boards upright on it. Align side board bottom edges to bottom board edges. Apply thin layer of wood glue, then drill φ3.5mm pilot holes from bottom board side and drive three 38mm coarse-thread screws per side (six total). Check right angles with carpenter's square during assembly.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 7 / 17

   Tip

   • Spread glue thinly about the size of a toothpick length; wipe any excess immediately with damp cloth.
   • Clamping side boards before drilling prevents shifting.
   • Ensure floor is flat and check bottom board horizontal with level before assembly.

   Watch out

   • Excessive glue causes paint adhesion problems; apply thinly and evenly.
   • Never screw without pilot holes to prevent plywood splitting.
8. 8

   Attaching the shelf board

   ≈ 20 min

   Insert shelf board (1164mm length) to marked position, aligning edges with side boards. Apply glue, drill φ3.5mm pilot holes from outer side of side boards and drive two 38mm coarse-thread screws per side (four total). Check shelf level with level tool.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 8 / 17

   Tip

   • Shelf length is 1164mm = 900mm top board width minus twice 18mm side board thickness; confirm dimensions before assembly.
   • Shelf interior is concealed; countersinks for screw heads are unnecessary.
   • If shelf pins for adjustable shelving are desired, drill multiple φ5mm holes accordingly at this stage.

   Watch out

   • Shelf too short causes wobble; too long causes side boards to bulge outward. Confirm cut length carefully.
   • Uneven shelf causes items to roll off; always check horizontal with level.
9. 9

   Attaching the top board

   ≈ 25 min

   Place the top board (1200mm width) on the box frame, aligning top edges of side boards. Drill φ3.5mm pilot holes from top board side and drive three 38mm coarse-thread screws per side (six total). Hide screw heads in countersunk holes; fill later with wooden dowels or wood filler for neater finish.

   Build the frame

   Tighten joints firmly

   AssembleSTEP 9 / 17

   Tip

   • Top board supports TV and is critical; increasing screw count to four per side (eight total) improves load capacity.
   • Fill countersinks with φ9mm wooden dowels; after painting, seams become invisible.
   • If TV is very heavy (over 30kg), add reinforcement 1×2 lumber underneath at center back of top board.

   Watch out

   • Installing top board reversed front to back causes grain mismatch; align grain direction before fastening.
   • 38mm screws are appropriate length for 18mm thick top board; longer screws risk penetrating shelf board below.
10. 10

    Checking right angles and diagonals

    ≈ 15 min

    Verify right angles at all four interior corners using carpenter's square. Measure internal diagonal lengths with tape; confirm diagonals are equal within 2mm tolerance. If misaligned, remove loosened screws, clamp frame to adjust, then retighten.

    Inspect

    No wobble ✓

    InspectSTEP 10 / 17

    Tip

    • Diagonal difference over 5mm indicates large distortion; must correct before back panel installation.
    • Clamping diagonally helps achieve right angles.
    • Enlarging pilot holes to φ4mm creates some play, easing frame adjustments.

    Watch out

    • Ignoring distortion here causes gaps at back panel corners.
    • Use accurate metal carpenter's square (aluminum or steel). Plastic ones have large errors.
11. 11

    Attaching the back panel

    ≈ 15 min

    Attach 4mm veneer back panel (900×450mm) to rear with staple gun or fine screws (φ3×20mm). Space staples every 30mm or screws every 100mm around edges and center. This secures right angles and largely removes frame distortion.

    Build the frame

    Check for square

    AssembleSTEP 11 / 17

    Tip

    • If distortion detected, clamp frame while attaching back panel to correct alignment.
    • Stapler works faster; a tool that shoots thin staples like heavy-duty stapler pins.
    • Align back panel grain horizontally for a clean overall look.

    Watch out

    • Do not install back panel reversed; front and back surfaces differ in color and grain.
    • Check for staples pushing through to the back and protruding; feel rear side after installation.
12. 12

    Drilling wiring hole (if needed)

    ≈ 15 min

    Drill a φ50mm hole in back panel for TV power, HDMI, and antenna cables with hole saw at position behind TV terminal area. If hole saw unavailable, drill multiple smaller holes and connect with a jigsaw.

    Drill a hole

    φ50mm

    DrillSTEP 12 / 17

    Tip

    • Apply edge banding tape around hole edges to protect cables and fingers.
    • Confirm position based on TV port layout for straight cable routing.
    • Align hole height with wall outlet for a neat appearance.

    Watch out

    • Incorrect hole positioning leaves cables exposed or inconvenient.
    • Hole saw slipped and peeled veneer; keep center drill bit firmly engaged.
13. 13

    Pre-paint surface preparation

    ≈ 15 min

    Lightly sand the entire assembled piece with #240 sandpaper, remove dust thoroughly with damp and dry cloths. Remove wood glue excess 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 do sample paint application on scrap piece; plywood absorbs finish differently from solid wood.
    • Water-based paints allow brush cleaning with water, easy for beginners.
    • Watco Oil retains natural wood texture; apply by rubbing in with cloth.

    Watch out

    • Glue spots repel paint; sand with #240 before painting to remove residue.
    • If dust remains before painting, surface will be rough. Clean thoroughly.
14. 14

    First coat of paint

    ≈ 30 min

    Apply paint or finish with brush or rag to all surfaces in order: top board → side boards → bottom board → back panel. Brush with grain in one direction for even coverage. Apply thin, even coats without thick buildup. Allow natural drying for at least 2 hours.

    Paint

    Watco oil / varnish

    PaintSTEP 14 / 17

    Tip

    • Use small containers for paint; leaving cans open forms skin which ruins paint.
    • If brush marks appear, switch to foam roller brush for smooth application.
    • Place work in dust-free area during drying; avoid fans blowing directly on surfaces.

    Watch out

    • Thick coats cause uneven drying and peeling later; always thin coats and two layers.
    • Direct heat or blowing air causes surface drying only with wet interior; avoid forced drying.
15. 15

    Sanding between coats and applying second coat

    ≈ 25 min

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

    Paint

    Watco oil / varnish

    PaintSTEP 15 / 17

    Tip

    • Light sanding removes surface roughness without removing paint layer.
    • Keep second coat thin to prevent runs and ensure uniform finish.
    • Avoid touching surface before drying to prevent fingerprints and dust.

    Watch out

    • Excessive sanding removes first coat; sand gently.
    • Thick second coats lengthen drying time, delaying subsequent work.
16. 16

    Attaching leg pads and anti-tip fittings

    ≈ 20 min

    Attach felt pads to legs to prevent floor damage and wobble. For earthquake safety, attach anti-tip straps or brackets at upper back of TV stand. Wall fastening by screws into studs is safest.

    Fix to the wall

    Anchor to studs

    InstallSTEP 16 / 17

    Tip

    • Felt pads cost about 50 yen at home centers; 10mm thickness absorbs floor unevenness well.
    • Anti-tip straps are available at 100-yen shops; more secure ones for TV stands cost around 1000 yen.
    • Screw anchors must be anchored into wall studs; drywall alone is insufficient.

    Watch out

    • Skipping felt pads causes floor scratches.
    • No anti-tip measures risk TV stand falling and TV damage during major earthquakes.
17. 17

    Final checks and installation

    ≈ 20 min

    Move completed TV stand to installation location. Check front-to-back and side-to-side level with level tool. Adjust wobble with felt thickness as needed. Place TV on top centered for even load, route cables through back hole, and test power. Initially place only light items and monitor for one week until finish fully cures.

    Done!

    Done — nice work!

    DoneSTEP 17 / 17

    Tip

    • Place TV centrally on top board to distribute weight evenly.
    • Use cable ties to organize cables routed through back panel hole for neat appearance.
    • Allow 50mm clearance front and rear inside shelf for ventilation if using AV units or disc recorders.

    Watch out

    • Finish takes one week to fully cure; avoid placing devices directly on finish on day one.
    • Inclined floors cause leveling issues; adjust felt pad thickness on sides individually to compensate.

Warnings

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

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