DIY BBQ TV-Chimney Module User manual

Instruction
Manual
Easy-to-Follow
TV-Chimney Module assembly

If you are still having trouble putting your module together, we are here to help. Contact us at 800-289-3492 or email [email protected].
Copyright Notice
Warnings
Notice of Limited Liability
Arbitration Agreement
This instruction manual is protected under Copyright Law of the United States of America.
This copy of the instruction manual is for the sole use of the original purchaser. A license to use the information contained herein is granted to
the original purchaser by the author.
No part of this instruction manual, including but not limited to, photographs, pictures, diagrams, or illustrations may be reproduced, copied or
transferred in print or electronically to third parties without the express written permission of the author. Any copying, retransmission, editing or
distribution without the express written permission of the author will terminate the license and all copies in the possession or distribution by the
purchaser will be considered unlicensed and therefore in infringement of U.S. Copyright Law.
Furthermore, if the purchaser wishes to use the information contained herein for the creation or supplement of business, whereby BBQ islands
would be part of the business, then the purchaser is not permitted to use or distribute any of the enclosed information within that business without
the express written permission of the author.
When working with metal, the edges are very sharp and may have small splinters across the edges. Be extremely careful when handling each piece.
It is highly recommended to wear safety glasses and gloves at all times while building your modules. Eye protection is required when cutting or
screwing metal pieces to protect against errant metal pieces and particles.
Keep children and animals away from the metal pieces and completed frame kits.
Please follow all manufacturer directions on how to properly install BBQ products.
Check with your local codes on construction for the required permits you may need for construction of your BBQ island.
Utility lines should only be installed by a licensed plumber or electrician per the code in your area. Do not forget to get a permit if required by
local laws or regulations.
Please read all directions on how to install your DIYBBQ island modules. Installation of the product is at your own risk; DIYBBQ, LLC is not
liable for misuse of the module frame kits nor for damage to any of your BBQ products.
NOTICE: DIYBBQ , LLC shall NOT be liable for incidental and consequential damages, directly or indirectly sustained to any person(s),
equipment, tools, or appliances during or after the installation of any BBQ island, related directly or indirectly to the installation and operation
of any BBQ island or appliances, nor for any loss caused by application of these goods not in accordance with current printed instructions or
for other than the intended use. DIYBBQ , LLC’s liability is expressly limited to replacement of defensive goods. Any claim shall be deemed
waived unless made in writing to DIYBBQ, LLC at 26520 ADAMS AVE., MURRIETA, CA 92562 within thirty (30) days from the date it
was or reasonably should have been discovered.
USE OF OR PURCHASE OF ANY DIYBBQ , LLC PRODUCTS, OR ANY GOODS AVAILABLE FOR PURCHASE THROUGH
DIYBBQ.COM REQUIRES THAT ALL CLAIMS BE SETTLED UNDER THIS BINDING ARBITRATION PROVISION, WHICH
AFFECTS YOUR LEGAL RIGHTS AND MAY BE ENFORCED BY EITHER PARTY.
In the event a dispute shall arise between DIYBBQ , LLC and any purchaser of any DIYBBQ, LLC product or good available through
diybbq.com, it is hereby agreed that the dispute shall be referred to a USA&M oce to be designated by USA&M National Headquarters for
Arbitration in accordance with the applicable United States Arbitration and Mediation Rules of Arbitration. The arbitrator’s decision shall
be nal and legally binding, and judgment may be entered therein.
Each party shall be responsible for its share of the arbitration fees in accordance with the applicable Rules of Arbitration. In the event a party
fails to proceed with arbitration, unsuccessfully challenges the arbitrator’s award or fails to comply with the arbitrator’s award, the other party
opposing party is entitled to costs of suit, including a reasonable attorney’s fee for having to compel arbitration or defend or enforce the award.

Useful Terms
Unassembled Module: A complete module set that must be completed from the ground-up.
Assembled Module: A complete module set in which all of the Perimeter walls and Cross Channel walls are pre-assembled prior to shipping.
Perimeter Walls: The front and back walls of a module.
Cross Channel Wall: The side walls of a module that connect to the Perimeter walls.
Track: The top and bottom pieces of a Perimeter or Cross Channel wall.
Stud: The sides and inside pieces of a Perimeter or Cross Channel wall.
Angle Brace: A piece that supports the tracks to the outer studs of the front and back walls of an unassembled module.
Countertop Stud (CTS): Pieces that slide perpendicular into a Catch Track to support the Appliance
Tracks as well as the appliance, door or drawer.
Dimple: The indentation around a precut hole within a track or a stud.
Web Holes: The small, precut holes, usually appearing in sets of three on the back side of a Cross
Channel wall that act as a guide for drilling when attaching Cross Channel walls to the front and back
walls of a module.
Assuage: The small creases that appear on the ends of a stud that allows for easier assembly (see image
to right).
Catch Track: An additional stud that runs perpendicular to Perimeter and Cross Channel walls within
the center of a module. (Used in specialty and cutout modules.) Assuage
Tools for Assembly
Proper Safety equipment is extremely important.
Always wear safety glasses and gloves when assembling your modules.
Using proper tools will make the project much easier to do and will help you obtain a properly built project. This list is of the basic tools
you’ll need to build your modules. You may use whatever tools you deem necessary to complete your project in the easiest way possible. All
tools listed here and others you may wish to acquire can be found at Lowes®, Home Depot®, Amazon and other on-line retailers.
A cordless impact driver will make steel frame assembly easier and help protect the edges of the HardieBacker®cement board from cracking
during installation onto the frame.
Professional Tips
Vise Clamps
Rafter Square
Cutoff Wheel
HammerPick
Cordless Drill
Spring Clamps
Tape MeasureAviation Snips
Magnetic LevelCarpenter Square
Marker

Outer
Studs
Inner
Studs
Tracks
Angle Braces
Cross Channel (CC) 1
Cross Channel (CC) 2
Screws
8 Angle Braces
8 Tracks (The tracks for the front wall do not include lips or slats for better maneuverability of studs and for easier cutout insertion.)
8 Outer Studs
10 Inner Studs (The inner studs for the front wall do not include any pre-drilled holes because they are adjustable, allowing for a universal
t of all cutouts.
2 Precut Appliance Tracks
132 Self-Tapping Screws
?
What’s in the box
Check List
Inner
Studs
Outer
Studs
Tracks
Angle Braces
Front Wall
Back Wall
Precut
Appliance
Tracks

5
Front Wall Assembly
Step
1
1Align the tracks so that the double dimpled holes are opposite one another.
Note: When aligned correctly, the text printed on each stud will read exactly the same.
Spread out the pieces to form a loose framework of the wall prior to attaching anything.
Note: Keep the inner studs o to the side. These will be placed later in accordance with the placement of the
television.
Place one end of the rst angle brace into the left stud.
Note: You may place the angle brace into either the stud or the track rst, however, it’s easier to maneuver the
brace into the opposite piece if you rst slide your angle brace into the smaller of the two pieces.
DIY BBQ
DIY BBQ
2
2
Step
3
Step
3
Professional Tip - Placing The Angle Brace
Avoid pinching your ngers in between the angle brace and the stud or track by
holding the angle brace at the top most half (as opposed to the bottom most half).
Place the angle brace with the inside facing the center of the stud or track. When
placed the opposite way, a gap will form and the angle brace will no longer be ush.
12
Gap

6
Slide the other side of the angle brace into the corresponding track and then easily swing the stud into place on the
edge of the track.
4
Step
4
1
23
Repeat steps 3 and 4 to attach the second angle brace to the opposite stud and track. You should now have two
L-shaped pieces. Slide the unattached ends together and make sure that all corners are ush.
5
5
Step
Professional Tip - Flush Corners
When placing two corners together,
the pieces may not always appear
completely ush. This is okay. The
integrity of the module will not be
aected.

7
Drill six (6) screws into the pre-drilled holes across the top and bottom tracks, as well as two (2) screws into the studs
where the angle braces rest (for a total of eight (8) screws)
Note: Begin with the Corner (see Inset), then nish screwing the angle brace before moving counterclockwise
around the frame.
6
6
Step
Flip the frame over and repeat step 6 on the opposite side. You should now have a completed frame wall with a set
of separate studs that will be added and adjusted once the entire module has been completed.
7
7
Step
Professional Tip - Uneven Holes
The pre-drilled holes in two pieces may not always align perfectly. If
this is the case, simply angle the screw into the opening of both holes
and then twist up while drilling.
12
3
12
3

8
Back Wall Assembly
Step
1
1Align the tracks so that the double dimpled holes are opposite one another.
Note: When aligned correctly, the text printed on each stud will read exactly the same.
Spread out the pieces to form a loose framework of the wall prior to attaching anything.
Note: Unlike the front wall, the center studs will be positioned within the frame and remain xed in place.
DIY BBQ
DIY BBQ
2
2
Step
Professional Tip - Aligning Cuts
When aligning the tracks for
the back of the module, if the
center cuts of each track are
misaligned, one of the tracks
needs to be ipped so that
the center cuts of both tracks
line up.

9
Place one end of the rst angle brace into the left stud.
Note: You may place the angle brace into either the stud or the track rst, however, it’s easier to maneuver the
brace into the opposite piece if you rst slide your angle brace into the smaller of the two pieces.
3
Step
3
1
2
Slide the other side of the angle brace into the corresponding track and then easily swing the stud into place on the
edge of the track.
4
Step
4
1
23
Repeat steps 3 and 4 to attach the second angle brace to the opposite stud and track. You should now have two
L-shaped pieces.
5
5
Step

10
Slide each center stud into the bottom track. Make sure that each of the precut holes line up.
Note: Each stud has a number reference, where Stud 1 will sit on the right with each number running consecutively
to the left. This isn’t necessary, but keeps everything organized.
6
6
Step
Slide the second L-Shape piece into the end of the bottom track.
Note: When sliding the stud into the track, the top track may bend up slightly. Do not worry. This will be adjusted
in the next step.
7
7
Step
1
2
3
4

11
Adjust the top of each stud so that they t comfortably inside the top track. Then use the butt of your palm to care-
fully but rmly hit each stud into the top track so that all precut holes in both the track and studs are aligned.
Note: If the studs do not slip right in when hit, readjust the studs and then reapply pressure to the track.
8
8
Step
21
3
4
5
Drill fourteen (14) screws into the pre-drilled holes across the top and bottom tracks, as well as two (2) screws into
the outer studs where the angle braces rest (for a total of sixteen (16) screws). When complete, ip the wall over and
drill sixteen (16) additional screws into the opposite side. You should now have a completed frame wall.
9
9
Step
x2

12
Cross Channel (CC) Wall Assembly
Step
1
1Align the tracks so that the double dimpled holes are opposite one another.
Note: When aligned correctly, the text printed on each stud will read exactly the same.
DIY BBQ
DIY BBQ
Spread out the pieces to form a
loose framework of the wall prior to
attaching anything.
2
2
Step Place one end of the rst angle
brace into the bottom track.
Note: You may place the angle
brace into either the stud or the
track rst, however, it’s easier to
maneuver the brace into the
opposite piece if you rst slide
your angle brace into the smaller
of the two pieces.
3
Step
3
1
2
Slide the other side of the angle brace into the corresponding stud
and then easily swing the track into place on the edge of the stud.
Recongure the pieces so that the track rests at the bottom.
4
Step
4
1
2
3

13
Repeat steps 3 and 4 to attach the
second angle brace to the opposite
stud and track. You should now
have two L-shaped pieces.
5
5
Step Slide the center stud into the
bottom track. Make sure that the
precut holes match up.
6
6
Step
Slide the second L-Shape piece into
the open end of the bottom track.
Note: When sliding the stud into
the track, the top track may bend
up slightly. Do not worry. This will
be adjusted in the next step.
7
7
Step Adjust the top of each stud so that
they t comfortably inside the top
track. Then use the butt of your
palm to carefully, but rmly, hit
each stud into the top track so that
all precut holes in both the track
and studs are aligned.
8
8
Step
1
2

14
Drill screws in all ten (10) pre-drilled holes. When complete, ip the wall over and drill ten (10) additional screws
into the opposite side. You should now have a completed frame wall.
9
9
Step
x2
Repeat steps 1 through 9 for the second CC wall. You should now have two complete Cross Channel walls.
10
10
Step

15
Complete Chimney TV Assembly
Step
1
1Make sure you have all of your assembled pieces.
Slide the le Cross Channel (CC) wall so that it aligns perpendicular to the edge of the le side of the back
Perimeter wall.
2
2
Step
Front Perimeter Wall Back Perimeter Wall Cross Channel (CC) Walls

16
Attach the CC wall to the back Perimeter wall by drilling at least ve (5) screws through the pre-drilled web holes
found on the inner side of the CC wall.
3
Step
3
Professional Tip - Attaching CCs to Perimeter Walls
Each outer stud of a Cross
Channel wall includes a series
of pre-cut web holes for easy
drilling. For strongest integrity,
use at least two screws in the
top set, one in the center set
and two in the bottom.
Repeat steps 2 and 3 to attach the second CC wall to the right back Perimeter wall.
4
Step
4
Drill
Inside
CC
Wall
Stud
TOP SET CENTER SET BOTTOM SET

17
Place the front Perimeter wall in place and drill screws through the web holes (as seen in step 3) to attach the front
wall to both CC walls.
5
5
Step
Drill
Inside
CC
Wall
Stud
Drill
Inside
CC
Wall
Stud
Find the two front wall studs and insert them into the frame. (Do not worry about where they are, these will be
adjusted in the next step.) Make sure that the open ends of each stud are pointing away the center (toward the outer
edges of the frame).
6
6
Step
Closed ends should point
toward the center

18
Drill four screws into the top and bottom of the studs (for
a total of eight (8) screws) to attach the inner studs to the
front Perimeter wall tracks.
8
8
Step
Measure the width of the studs from the inside edges (see marked) so that the space between them is a few inches
larger than the length of the television to be placed.
Note: You may want to measure from the center stud to the outside stud on each side to make sure they are
centered within the frame.
7
7
Step
Length between studs should
be a few inches larger than the
length of the television
The space between the inner
studs and the outer studs
should be equidistant.
Professional Tip - Drill-
ing Screws Into Metal
Though the screws you’ll use to assemble your
cutouts are self-tapping, it can still be dicult
to drill without a guide. If you nd it dicult to
drill your screws into the metal, start by placing
the end of a pick where you would like to place
your screw and gently tap the end of the pick
with a hammer. This will make a small indent
in the metal that you can rest your screw into.
1
5
7
6
8
2
3
4

19
Find the rst precut track and place it in between the inner front Perimeter wall studs near the bottom of the
module so that the top (ush side) of the precut track aligns with the marks made in step 9. (The top edge of the
precut track should be 12” from the bottom.) Make sure the open side of the precut track is facing down. If you
want to make sure the precut track remains in place while attaching it to the Perimeter wall studs, add at least one
clamp to secure it to the studs. Clamp(s) may be removed after step 12. (See inset)
Note: Turn to page 25 for instructions on how to measure (depending on size of television) and cut the second
end of your precut track.
10
10
Step
Measure 12” up from the bottom of the module and mark each stud accordingly with a marker.
9
9
Step
Open side should be facing
down.
12”
12”

20
Use a level to make sure that the precut track is completely level to the ground. (See Inset)
11
11
Step
Drill four (4) screws to the precut
track to attach the precut track to
the inner Perimeter wall studs.
Note: You may now safely remove
any clamps used to hold the precut
track in place.
12
12
Step
1
32
4
Measure the height of the television
and mark that height on each of
the front wall from the top of the
bottom track placed in the previous
steps.
Note: You may add an inch or two
to make sure that the television sits
easily within the space.
13
13
Step
Height here should be an inch
or two more than the height of
the TV