One of our viewers, Julie from Caloundra, asked for some help making a TV entertainment unit. Shirl's stepping in and making Julie a TV unit with a difference — it's shaped like a Melbourne beach hut.
STEP BY STEP
1 For a superior finish, take the material list to your local cabinet maker and have all pieces cut to size. Your cabinet maker will also be able to assist with drilling the hinge holes in the back of the doors (4 holes per door will be required). The hole spacing will be determined by the door mechanism specifications.2 Next, mark out and rout the "V" grooves. These will give the appearance of tongue and groove V jointed panels. The grooves need to be positioned in both ends, both doors and later in the construction of the front top panel. 3 Take the two end pieces and divide by the number of boards as desired. Remember, an easier way to divide a non-equally divisible size by a certain number is to move the tape measure at an angle until an equally divisible number is achieved, then step off the appropriate proportion. 4 Clamp a straight edge to the work piece the set distance away from the line. To determine the set distance, measure from the centre of the cutter to the outer edge of the router. The depth of the cut should be approximately 3mm. Continue this procedure with the other end and the two doors. 5 Pre-drill, glue and screw the ends and top and bottom. Be sure not to position screw holes in the previously routed grooves. Screw back to unit 6 If you are drilling the doors for the hinges, determine hinge centres and the distance from the edge of the door. You can use a specific 35mm hinge boring bit or modify a spade bit by reducing the length of the point. The length of the point will need to be reduced to eliminate any nasty surprises through the face! 7 Fit the pivot door slide mechanism as per manufacturers instructions. So the doors slide easily, the runners must be screwed parallel with the end. Use the elongated holes first, test doors, then use the remaining holes to lock in place. 8 Attach the appropriate guides as per manufacturers instructions. You will also need to attach a block to the inside of the ends to act as a door stop. This will prevent the handle contacting the front edge of the cabinet when retracting doors. 9 Glue and screw internal shelves to vertical divisions, according to your dimensions. Gluing and screwing two pieces together strengthens the TV shelf. A chamfer was machined on two adjoining edges to form a "V" groove (See fig. 1). 10 Slide the completed internal shelving unit into the cabinet and fix in place, making sure it is centrally located. The two equal spaces on either side are the voids to accommodate the retracted doors. 11 Construct the base stand by attaching the rails to the legs. The rails are positioned on the edge and can be attached by dowelling or concealed pocket screws. Attach base stand to underside of cabinet. 12 Nail and glue drawers, then attach runners. The face of the drawer must be set back 16mm to allow for a false front. We used Shirl's special "half hole" handle. 13 Sit the front roof panel on top of cabinet, and with the doors in their closed position, transfer the position of the grooves from the doors to the panel above. It is important to rout the grooves on the panel before cutting out roof slope. 14 Cut roof slope and duplicate shape for back support. Connect the two by attaching bracing pieces (these will also be used for fixing the roofing material). 15 Attach roof frame to top of cabinet, then attach the roofing material to the frame. Make a timber bead to form a ridge cap and battens to conceal dangerous corners. 16 Fill all screw holes with a two part filler. Avoid using wood putties as they will shrink and become unsightly. Finally, sand and apply your favourite paint finish.
Diagrams
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