Adam Henley X-Door Rustic TV Console User manual

28" (700)
59-1/2" (1488)
20" (500)
X-Door Rustic TV Console
by Adam Henley - ThePowerToolWebsite.com

T o o l s & J i g s
�
�
�
�
�
�
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Table Saw
Track saw or Circular saw
(for breaking down ply)
Table Saw Sled
Vertical Cut Fence
Pocket hole jig
Brad Nailer
Router (optional)
H a r d w a r e & M a t e r i a l
�[1] full sheet 3/4" (19) plywood
�[1] half sheet 3/4" (19) plywood
�[1] half sheet 1/4" (6) plywood
�[6] 3/4" x 8" x 8' (19 x 200 x 2400) board
�-----------
�1-1/4" (30mm) pocket screws as needed
�1-1/4" (30mm) brad nails as needed
�Wood glue as needed
�[4] door hinges
�[2] door knobs
�[16] shelf pins
�[2] magnetized door stops
�1/4" (6) spiral router bit or straight cut bit
C u t L i s t
*FF = Face Frame
*
1
X-Door Rustic TV Console
Reference 1

backstop
backstops
2
X-Door Rustic TV Console
Cutting Diagrams 1

3/4" (19)
3/4" (19)
3
X-Door Rustic TV Console
Cutting Diagrams 2

1/4" (6)
4
X-Door Rustic TV Console
Cutting Diagrams 3

S5
S6
S6
S5
C4
C4
C4
C4
C13 (X4)
S4
S4
S3
C10
C12
C10
C7
C8
C9
C9
C9
C9
5
X-Door Rustic TV Console
Exploded Views

C5
C5
C6
C6
S2
S7
S7
6
X-Door Rustic TV Console
Exploded Door

C13
C13
C13
C13
Edge glue and clamp the Top Boards (C13) together as shown.
7
X-Door Rustic TV Console
Top Detail

S5 (x2)
S6 (x2)
2"(50)
3/4"(19)
2"(50)
3/4"(19)
18" (450)
27-1/4" (681)
18" (450)
27-1/4" (681)
Pocket hole shelf pin hole
locations are approximate.
8
X-Door Rustic TV Console
Upright Details

View from left
View from right
FRONT
FRONT
1
S6
S6
S6
S6
S5
S5
S5
S5
C4
C4
C4
C4
C4
C4
C4
C4
16" (400)
22" (550)
9
X-Door Rustic TV Console
Frame Assembly

1-1/4" (31) overhang
2
3
S3
S4
S4
C13
10
X-Door Rustic TV Console
Bottom & Top

Proud by
3/4" (19)
BACK
FRONT
Flush
4
C12
C10
C11
C10
C11
C12
11
X-Door Rustic TV Console
Side Trim

BACK
FRONT
5
6
C1
C2
C8
C7
C9
C9
C9
12
X-Door Rustic TV Console
Back Trim & Face Frame

7
8
S3
S3
S4
S4
C3
C3
C3
13
X-Door Rustic TV Console
Shelves

9
S1
S1
14
X-Door Rustic TV Console
Backing

11" (275)
1/2" (13)
1/4" (6)
1/4" (6)
3/4" (19)
2-1/2" (63)
22-1/4" (556)
2-1/2" (63)
1/2" (13)
11" (275)
10" (250)
1/2" (13)
10
11a
11b
C6
C5
C5
15
X-Door Rustic TV Console
Door Rails & Stiles

12
13
C6
C6
C6
C6
C5
C5
S2
16
X-Door Rustic TV Console
Door Assembly

10" (250)
22-1/4" (556)
105°
37°
143°
14
15
17-1/4" (431)
15" (375)
C6
C6
C5
C5
S2
S7
S7
17
X-Door Rustic TV Console
Door Assembly 2

16
Magnetic door stop
Small wooden door stop
(3/4" x 3/4" x 2" block)
(19x19x50)
18
X-Door Rustic TV Console
Final Hardware

P r e W o r k
Assemble the Top
See page 'Top Details'.
If you're edge-gluing boards and building a regular panel, you can optionally reinforce it using biscuits, dowels, or
pocket hole joinery (in addition to edge-gluing each piece).
You can also incorporate breadboard ends, or you could use plywood for the top but be sure to add veneer
edge banding to cover the sides. If you use either of these alternative methods, adjust the material and cut list
as needed.
Prep the Uprights
See page 'Upright Details'.
Cut the notches in the corners as shown in the Upright Details page, on each S5. Add pocket holes as shown
(pocket holes should not be visible from the middle section of the console).
Drill the pin holes as shown for supporting the shelves later. You can also add the pin holes later in the
construction process if preferred.
Main Assembly
Step 1 - Frame Assembly
Add the pocket holes to the ends of each C4, and to each Upright (S5 and S6) as shown.
Using pocket screws, assemble the pieces as shown.
Step 2 - Bottom
Glue 2 Side Shelves (S4) and one Mid Shelf (S3) down to the bottom stretchers (C4). You can use brads instead
of clamping if preferred.
Step 3 - Top
Position the top so there's 1-1/4"(31mm) overhang on the front, and both sides. There should only be 3/4"(19mm)
overhang on the back.
Secure the top (C13) to the uprights (S5 & S6) using 1-1/4" pocket screws.
Step 4 - Side Trim
Glue and brad nail the Side Rails (C10 & C11), and the Side Stiles (C12) to the assembly.
They should be flush with the front, and should overhang by 3/4" (19mm) in the back.
Step 5 - Back Trim
Glue and brad the Back Rails (C1 & C2) to the stretchers as shown.
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X-Door Rustic TV Console
Assembly Instructions 1
Prep The Shelves
You can get veneer edge-banding to attach to the front edges of your shelves, so the plys are not exposed.
Alternatively, you can cut thin strips of wood and glue and brad nail them to the front edges of the shelves.
Or you can build the shelves from solid wood, each as a solid wood panel. Doing this will require some
changes to be made to your cut list and diagrams.