Thread: Enclosed TV Cabinet

I decided I wanted to build subframes top (to hold sides and attach Top) mid section (to support TV and sound bar) and lower section (to support the Electrical devices)
I will be using dovetails made by my Leigh Dovetail Jig

Because I have to have the Rails (horizontal long piece) to rout the Half Pins I needed to build a spacer box to put my DT Jig on.

I pulled out some mahogany and started rough cutting and then surfacing one side flat on jointer then one edge at 90 deg then I was able to bring down to desired thickness and width.

These photos are showing machining for insertion of the dominos to assemble the spacer box.

The finished spacer box with rails inserted for routing half pins.

I moved on to machining the Panels to size and the stopped dovetails and half pin sockets at the top.

I also used a twin cutter in pedestal drill to cut the circle for the cut out at bottom of panel. This tool works a treat.

This is a photo of the basic cabinet dry fitted.

Originally Posted by Woody1

I also used a twin cutter in pedestal drill to cut the circle for the cut out at bottom of panel. This tool works a treat.

I have a single cutter version. It can get out of balance at times. I imagine the twin cutter design eliminates that problem?

Yes. Found it to cut smoothly. I selected a slowish speed and did not force it.

I have started on one of web frames. Once again pine from Bunnings. I used 2 dominos in each end of small vertical piece and I left about a 5mm gap to allow for expansion across the width of Ends for seasonal movement.
I also am routing a recess to allow for inserts to fill the void and make them flush.
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I decided to build and install the lower insert that sits under the lowest shelf and runs the full length to each end. This is a pic if using the twin cutter to make the internal radius at each end.
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It was time to use the Bandsaw to to cut between the two circles.
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Once Band sawing complete I took it over to workbench to clean up and use the shooting plane to get ends square (or I should say at the angle required to make it fit. I use playing cards to alter the angle very slightly)and for final fitting between the two ends.
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I thought I would post some pics of various stages of the main carcase being assembled.
Note the second last photo has the under the lower sub frame the installed fill in piece between the two end.
Apologies for posting all photos at once without having explanation between but I mucked up not thinking properly

These next couple of pics show the small router I used with 1/4 inch bit which will allow the hold down clip used to secure the 32mm Top onto the sub frame.

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Second Pic
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The following pic shows the Top mounted onto the subframe with the hold down clips securing the top.
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It was time to focus on the doors. If I had four big doors there would not be enough room to open them and close them comfortably. I decided to try making folding doors so as that would reduce the actual opening by half. I also decide to use this black perforated Aluminium as an insert.
I went to Bunnings and purchased some premium pine and started machining styles and rails to size in prep for dominos.
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So there will be 8 doors in total, 4 large for the top section and 4 small for the lower section where all the Electrical components are.
Here are pics of some of the large doors clamped up and glue drying.
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I bought some good quality hinges and started machining the rebates for them.
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Another pic of machining rebate for hinges
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I finally Got the large doors fitted. I used ball and catch to hold doors closed and installed some Bunnings Handles.
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This pic shows the Folding Door opened.
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It was time to remove them all and insert the perforated black Aluminium. I had previously made some quarter inch quad which was alright for the front of the door but the back it was a little bit large so I had to plane down with the spoke shave. I brad nailed it all in place.
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This is the pic with top 4 doors fitted. I did the same for the lower smaller 4 doors.
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The Final Pics with the Doors open showing TV and sound bar at top and all the other electrical components at the bottom.
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All Done Wife very happy. A lot of lessons learnt but fun building.

Looks very smart. Well done!

The most important part is that the missus like it. In that event it doesn't really matter what the remainder of us think.

How did you apply the white? Is it paint or lacquer?

Thank you for your kind words John
I applied Porters Paint with a brush but painting is certainly not my choice.
You are 100% correct that happy wife is all that matters.
I have started on a Country Hutch for my Daughter and will definitely be spraying it after receiving all the excellent info from yourself. I have no idea how long it will take to build as so many distractions come along the way but I will keep taking photos as the build progresses.

Cheers
Graeme