Project 7: Create a self supporting TV stand.

2018-03-15

Objective:

To economically build a self supporting TV stand.

For anyone who set-up a LED/LCD TV using the included stand knows it may not position to location in mind, and in general it is difficult once in place to add or remove cables. I intended to remedy this by using a full-motion TV wall mount. However, drilling into the wall was not appetizing so I decided to build a self supporting TV stand of my own design.

Only hand tools were used to build this stand. It works well but next time I would build 4 inches higher to position TV modestly higher.

Structure:

44 in. High

30 in. Deep

48 in. Wide

100 lbs Mass

250 lbs Capacity, mass extended 24" from top members.

Materials:

1. Sanus Full Motion TV Wall Mount, Model SLF9-B1. Cost $90

2. 4x 2" X 6" X 8' Southern Yellow Pine (SYP) Lumber. Cost $3.98 ea.

3. 3/4" X 30" X 48" Plywood. Cost $33 ea.

4. 3x 36" Threaded Rod 1/4-20 UNC. Cost $1.97 ea.

5. 20x 1/4-20 UNC Nuts. Cost $1.08 all

6. 20x 1/4 Washers. Cost $1.08 all

7. 10x #10 2" Wood Screws. Cost $0.80 all.

8. 4x 3/8" X 3" Oak Dowels. Cost $0.80 all.

9. Wood Glue. Cost $0.25

10. Oil Based Primer. Cost $4.00.

11. Oil Based Paint. Cost $4.00.

Total cost of all materials used $157 USD.

Tools:

1. Makita 7 1/4 Circular Saw

2. Makita 4 1/2 Angle Grinder

3. Ryobi Jig Saw

4. 3/8 Drill, corded

5. Drill Bit Set

6. 2x 4 in. C-Clamps.

7. 2x 8 in. C-Clamps.

8. Ratchet Wrench

9. 7/16 socket

10. 7/16 wrench

11. Aluminum Speed Square

12. Screw Drivers

13. Wood Chisel

14. Sand Paper, misc

15. 4.5" X 0.045" Cut Wheel

Total cost of all tools if all bought new for project is approximately $400 USD.

Design:

Note 1: The joining of the 3 45 in. cross members to the 2 vertical members are using 1/4 threaded rod, two spaced centered and 4 in. apart. Total of 12 1/4 X 6.5" rods required. Found you want rod extending about 1/2 each side for washer and nut.

Note 2: The joining 2 28.5 in horizontal support members to the 2 vertical members are using 1/4 threaded rod, four spaced centered 4 in. apart vertically and 2.5 in. apart horizontally. This joint is important to react the torque from the TV support arm. IMPORTANT, rod is already extending through the bottom cross member. Make sure that new holes for the horizontal members do not intersect the installed rods from the cross-member. If design was revised this joint would be modified.

Note 3: As an alternate the last cross-member 48 in. long can be screwed to the two 28.5 in. horizontal members using #10 X 2.5 in. wood screws.

Note 4: The 2 11.75 in. vertical legs are connected to the 28.5 in. horizontal members using 3/8 oak dowels.

Note 5: This design was created manually using graph paper. However, free CAD tools could be used to do this. I tried using FreeCAD. With this software I was able to get an accurate solid model but the drawing tools were not user friendly. I gave up after several hours trying to produce manufacturing drawings. Posted are graphics of this work.

FreeCAD:

Procedure

1. Cut all 2X 6 lumber to length:

1x 48 in. long

3x 45 in. long

2x 44 in. long

2x 28.5 in. long

2x 11.75 in. long

2. Cut 3 notches into the width of the 44 in. To do this set the cutting depth on circular saw to 1.5", the width of a 2X6, then mark out 5.5" for the notch. Then do many cuts over the width of notch, this leaves many thin sections. Remove thin sections of wood using a hammer and then chisel flat. Do this for all 6 notches in both vertical members.

3. Lay the vertical beams, notches facing up, on the shop floor. Fit the three cross members into the notches. Measure and ensure the layout is as desired. Mark-out and drill holes for the 1/4-20 UNC rod. I used a 5/16 in. Titanium (coated in titanium ceramic) Pilot-Point Drill Bit for plenty of clearance. I drilled the cross-members and vertical members separately using a Black & Decker hand drill. Take your time as it is not hard to drill off target.

4. Cut 12 pieces of 1/4-20 UNC threaded rod into 6.5" lengths. Carefully stand up the structure, may take two people if your cross members do not fit tight. Fit the threaded rod add 1 washer and nut to each side. Tighten each rod using the socket and wrench to about 150 in·lbs.

5. First cut 4 3/8" wood dowels 3 in. long. Stand the two 28.5 in. long horizontal members on shop floor. Place the 48 in cross member on the two horizontal members and ensure it is square. Drill two 7/16" diameter holes, each side, to 3.125" depth through the cross member into the horizontal members. Center holes to horizontal members and space 1" from top, and 2" between two pins, this leaves enough wood for the leg dowel pins. Apply glue to the 4 holes. Hammer the dowels in place and check to make sure structure is square. Let dry for 12 hours.

6. First cut 6 3/8" wood dowels 3 in. long. Drill three 7/16" diameter holes to 1.5" depth, one should be in the cross-member and two in the horizontal members. Mirror the holes on the face of each of the two legs. Apply glue to the holes in one leg and fit three dowel pins. Apply glue to the holes in cross and horizontal members and fit to the leg dowels. Ensure tight fit and square. Repeat for the other leg.

7. Stand the support assembly (vertical members), place back near a wall in case the structure tips. Slide the horizontal members into place. Drill out holes for the 1/4-20 UNC rod, 4 each side. Four 5/16" holes spaced centered 4 in. apart vertically and 2.5 in. apart horizontally. This joint is important to react the torque from the TV support arm. IMPORTANT, rod is already extending through the bottom cross member. Make sure that new holes for the horizontal members do not intersect the installed rods from the cross-member. Fit the threaded rod add 1 washer and nut to each side. Tighten each rod using the socket and wrench to hand tight.

8. Prime and paint structure. I used oil-based paint for the durability.

9. Install Sanus TV bracket to the TV of your choice.

10. Install Sanus TV Support base to frame as per manufactures instruction.

11. Unit likely will not fit through the door so unbolt the 8 1/4 rods and remove the table for support assembly. Move support assembly indoors near it's final installation location.

12. Fit the table to the support assembly. Insert the 8 1/4" rods with nuts and washers. Tighten each rod using the socket and wrench to about 150 in·lbs.

13. Move to final position. Insert TV to the support base. Insert the lock screw and tighten hand tight. Loosen top and bottom rotation screws, level, and retighten.

14. Add sound system, and use Sanus's cable management shrouds.

Conclusion

Time to enjoy.