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Store home electronics
gear in style
F H
/ x 25/16"
3 4
7011/16" B notches
171/4"
A
D
B
/ " notches
3 4
1 / " deep
3 4
F
C
80" 251/4"
80"
F A
F
B
D
D
/ " holes
1 4
/ " deep
1 2 253/16"
for shelf
supports A
/ " dadoes
3 4
/ " deep
1 4 F
B G
H 411/16"
/ " notch
3 4
1 / " deep
3 4
page 2 of 12
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#8 x 11/4" F.H. B
wood screws F
ASSEMBLY G
DETAIL A Miter end of cleat to 45 .O
F countersunk 45 bevel
1/4" O and P
1/4"
1/2"
3/4"
W
o
45 miters
17/32" 1/4"
1" S and T
101/2"
SIDE PANEL
(BACK VIEW) U and V
1/2" rabbet
1/4" deep
o
Rip 45 miters after
panel is assembled.
O and P
S and T
1/2" rabbet
This edge will go 1" 1/2"
next to doors. deep
page 3 of 12
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Note: We designed this cabinet to
house most 27" televisions. For some
Bill of Materials for Carcase Assembly models, though, you’ll have to remove
Matl.
Finished Size the hinges from the cabinet before
Qty.
Part sliding the TV into place.
T W L
Let’s begin with four
A shelf blanks ‡" 21‡" 42¤" OP 4 identical shelves
1 Using the Parts View on page 8 for
B banding ‹" ‡" 27‡" O 4 the shelf (A), lay out and cut the four
shelves to the same exact shape. See
C*sides ‡" 21‰" 80" OP 2 the Cutting Diagram for how we cut
four blanks from one piece of 4×8
plywood. (We cut one shelf to exact
D supports ‡" 4" 80" O 2 shape, and then cut the other three
slightly oversized. Then, as shown in
E back ‹" 13›" 70Ø" OP 1 photo A, we used our handheld router
fitted with a piloted straight bit to rout
F cleats ‡" ‡" 8Å" O 16 the other three shelves to the exact
shape of the first.)
G cleats ‡" ‡" 27‡" O 2 2 Cut the banding strips (B) from solid
stock, and glue and clamp them to the
front edge of the shelves (A), making
H cleats ‡" ‡" 3Œ" O 8 sure the top and bottom surfaces are
flush.
*Cut parts marked with an * oversized. Trim to finished
size according to the how-to instructions. Cut the carcase pieces,
and assemble the carcase
1 Cut the carcase sides (C) to 21fi×80".
Materials Key: OP–oak plywood, O–oak. Lay out the dadoes using the
dimensions on the Side (A) portion of
Carcase Supplies: #8×1" flathead wood screws, the Parts View drawing on page 8. Fit
#8×1‹" flathead wood screws, #8×1fi" flathead your tablesaw with a dado blade and
cut the dadoes where marked, taking
wood screws. care to keep the dadoes positioned
exactly the same in each.
2 Using your tablesaw, bevel-rip the
back edge of each cabinet side (C) to
final width (21‰") at 45°, being
careful to rip the bevel on the side
opposite the dadoes.
3 Cut the corner supports (D) to size,
bevel-ripping the front edge of each
at 45°. Mark the notch locations on
one, making sure they align with the
dadoes in the sides (C). Clamp the two
supports face-to-face, and cut the
notches in both at the same time.
4 If you plan on adding the adjustable
shelf (Z) later, drill ‹" holes fi" deep
for the shelf clips in parts C and D
where dimensioned on the Parts View
drawing.
5 From ‹" oak plywood, cut the back
page 4 of 12
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CUTTING DIAGRAM
421/8"
A 21 / "
3 4
A
A A
E
/ x 48 x 96" Oak plywood
3 4 / x 48 x 96" Oak plywood
1 4
I I
O O P
C Q Q R
J
Q Q R
C Z
O O P
/ x 48 x 96" Oak plywood
3 4 / x 48 x 96" Oak plywood
3 4
D
D
/ x 91/4 x 96" Oak
3 4
F G F G F F
B, AA ,and BB (1/4 x 3/4" banding strips)
N M N
/ x 51/2 x 60" Oak (2 needed)
3 4
page 5 of 12
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shown in photo B and in the Assembly
A detail accompanying the Carcase
drawing.
Secure the notched supports to the previously installed shelves by driving wood screws through the
previously drilled cleats.
page 6 of 12
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FRONT FILLER CLEAT
273/4"
2" 8" 8" 2"
TOP VIEW
G 3/4"
3/4"
page 8 of 12
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Bill of Materials *Cut parts marked with an * oversized.
Trim to finished size according to the
Matl.
Finished Size
Qty.
Part how-to instructions.
T W L
MOLDINGS Materials Key: OP–oak plywood,
O–oak, M–maple.
I* filler strips ‡" 4‡" 28Á" OP 2
Supplies: #8×1‹" flathead wood screws,
J* filler strips ‡" 4‡" 10Œ" OP 4 #8×1fi" flathead wood screws, #8×1‹"
panhead wood screws with flat washers,
K* banding ‹" ‡" 28Á" M 2 hinges (see description below), brass
shelf supports, gloss black paint, clear
L* banding ‹" ‡" 10Œ" M 4 finish.
M* molding ‡" 5" 29„" O 2
Buying Guide
N*molding ‡" 5" 11‹" O 4 Hinges. Self-closing 165° Grass
concealed hinges. Six pair needed.
PANELS AND DOORS Catalog no. CH1202. For current price,
contact Constantine, 2050 Eastchester
O panels ‡" 10fi" 25›" OP 4 Road, Bronx, NY 10461, or call 800/223-
8087 or 718/792-1600 to order.
P panels ‡" 10fi" 17›" OP 2
Q doors ‡" 13‹" 25›" OP 4
R doors ‡" 13‹" 17›" OP 2
S* banding ‡" 1" 25›" M 4
T* banding ‡" 1" 17›" M 2
U*banding ‹" ‡" 25›" M 12
V* banding ‹" ‡" 17›" M 6
W*banding ‹" ‡" 11‹" M 12
X* banding ‹" ‡" 13‡" M 12
Y handles ‡" 2" 2" M 6
ADJUSTABLE SHELF
Z shelf ‡" 21›" 27¤" OP 1
AA banding ‹" ‡" 27fl" O 1
BB banding ‹" ‡" 14" O 2
CC cleats ‡" 1fi" 10" O 2
page 9 of 12
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#8 x 11/4" panhead wood screws Space panels
#8 x 11/4" F.H. wood screw with #10 flat washers 7/64"pilot
3/32"
apart (use holes
Corners along this J spacer blocks). 1/2"deep
edge of cabinet have o H C 1/4" mounting hole
no miters (they are 90 ). C N
P T
G A C
I
J
B
N M A O
L #8 x 11/4" panhead B
22.5o miters K P *45o miter
A wood screw
#10 flat washer
S
V
W PANEL D
D MOUNTING DETAIL
B
F
P *NOTE: See profile on Side Panel
E
drawing for miter configuration.
T D
O
165 self-closing inset hinges
O (see Mounting the Doors drawing)
A
*45o miters
W B
X
F
Brass shelf V R
U O S supports
N
#8 x 11/4" panhead
wood screw with R V V
#10 flat washer A
K
F B
G Y
W *45o miter H
X
L
J I
M U
Q
O N o
22.5 miters
Q
S
22.5o miters U
Drill 7/64" pilot holes 1/2" deep for
W #8 panhead and F.H. wood screws.
U
U EXPLODED VIEW
M K and I
22.5o miters
page 10 of 12
TM
Bore the hinge holes where marked
C and as shown in photo D. (Notice how
we marked stop lines on our drill-press
fence to keep the holes exactly 2fi"
from the top and bottom ends of the
doors.)
5 Fit the hinges into the holes just
bored in the back face of the doors.
Using the screws supplied with the
hinges, drill pilot holes, and screw the
hinges in place.
6 Attach the base plate of each hinge
to the carcase. See the Mounting the
Doors drawing for reference.
Following the instructions supplied
with the hinges, fit the hinge on the
base plate, and secure in place. Make
With the cabinet on its back, use spacers to create equal gaps
between the molding and banded side panels. the alignment adjustments as explained
in the instructions.
Inside of cabinet 21/4" O
D
S It’s time to machine
MOUNTING the door handles
THE DOORS N U Q
1 From ‡" maple, cut seven 2" squares
Back side
of door for the handles (Y). Use the extra
A handle blank to verify your machine
21/2" 13/16" settings in the following steps before
B
o
165 self-closing machining the other handle blanks.
inset hinge 3/32" pilot hole 2 Fit your table-mounted router with
base plate 3/8" deep 13/8" hole
3/32
x 3/4 x 11/2" 1/2" deep a ›" cove bit and fence. With the good
spacer block side up, rout the end grain first on each
handle blank to reduce chip-out. (To
M 21/2" safely hold the 2"-square handles when
X
o
routing, we used a wood handscrew
165 self-closing inset hinge
clamp.) Next, rout the adjoining two
edges on each handle blank.
1/4 x 3/4" banding along X
3/4" 3 Using your drill press with a fence
DOOR all edges of doors 1/4" and stop, drill a 7⁄64"pilot hole centered
on the back side of each handle. See
7/64" pilot hole
1/2" deep, centered
the Door drawing for reference. Sand
the handles smooth.
3/8" cove 3/8" deep
131/4" OK, let’s add the
2"
shelf and the finish
1 For additional storage, construct the
shelf (Z, AA, BB, CC) in the
Hinge mounting hole configuration shown on the Adjustable
(see Mounting the Doors
2" drawing above for location) Shelf drawing. To allow us to get all
the panels and shelf (Z) from one piece
#8 x 11/4" F.H. of plywood, we banded the ends to get
Y wood screw
2" the necessary length.
2" Q and R 2 Remove the hinges from the cabinet
5/32" hole, countersunk and doors. To ensure correct placement
Back side of door when reassembling, mark
U and V
corresponding marks on the hinges
and their mating holes.
page 11 of 12
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3 Remove the knobs and spray-paint
D them a gloss black.
4 The back of the cabinet (E) should
still be off. If not, remove it; it’s easier
to finish the cabinet with the back
panel not in place. Determine what
you’ll need for cord holes through the
back, and cut the access holes.
Depending on your television, you also
may need to cut an opening through
the back (E) for the rear of your
television to extend through. Sand the
back smooth.
5 Apply finish to all the pieces. (We
applied three coats of semigloss
lacquer, sanding between coats.)
Mark the centerpoints on the doors, and bore a pair of holes in the 6 Reattach the hinges and handles.
back side of each door for attaching the hinges later. A fence keeps Screw the back panel in place.¿
the holes aligned.
33/4"
Produced by Marlen Kemmet
275/8" Project Design: James R. Downing•
10" Illustrations: Kim Downing, Lorna Johnson
Graphic Design: Jamie Downing
AA ©COPYRIGHT MEREDITH CORPORATION 1998
CC
BB 14"
The purchase of these plans does not
271/8"
O transfer any copyright or other ownership
45 interest in the plans, the design, or the
213/8"
Z
finished project to the buyer. Buyer may
BB neither reproduce the plans for sale nor
11/2"
7/64" pilot hole 3/4" deep offer for sale any copies of the finished
project.
CC
o
45 bevel
5/32" shank hole, countersunk
SHELF
LAYOUT 73/8" 123/8" 73/8"
45o
73/8"
Z
ADJUSTABLE SHELF
213/8"
271/8"
14"
Cleat CC locations
Banding BB locations
Banding AA location
page 12 of 12
TM