How to build a fully enclosed-front four-box cabinet

Cut list

Step by step

1. Verify fit and shape passages

   Approve the retained four-box envelope and internal route with the entire front closed before shaping the side passages.

   • Mock up the 84 1/2" × 32" × 44 1/4" cabinet beneath the actual television.
   • Test the internal landings with the entire front closed and all four boxes present.
   • Mark the paired side passages from the cut drawings.
   • Clamp each panel over supports clear of the blade.
   • Drill 1/2" starter holes just inside the opening corners.
   • Saw each opening with a jigsaw against a clamped straightedge.

2. Shape the edging miters

   Prepare the front edging corners with matching miters.

   • Mark the outside long points on the three edging pieces.
   • Clamp the miter box firmly to the bench.
   • Support the molding along its full length.
   • Saw the marked 45° miters with the hand saw.
   • Dry-fit the front corners against the top.

3. Glue the access doors

   Glue six full-height pine access doors to close the entire cabinet front.

   • Arrange each door's boards with their best faces outward.
   • Spread a thin glue film along the mating edges.
   • Clamp each panel between straight protective cauls.
   • Wipe away the squeezed-out glue.
   • Allow the glue to cure for its stated clamping time.

4. Attach the top cleats

   Fasten the concealed top cleats while the side panels are accessible on the bench.

   • Lay each side flat on a padded bench.
   • Align its cleat flush with the top and 1 1/2" from the front.
   • Clamp the cleat against the panel.
   • Drill clearance and pilot holes at the marked positions.
   • Drive the 2" screws through the panel into the cleat.

5. Assemble the module bases

   Join each module's side panels to its front and rear plinth rails.

   • Stand each pair of sides on a level assembly surface.
   • Clamp the front and rear rails between the sides.
   • Align the rail bottoms with the panel bottoms.
   • Drill the marked clearance and pilot holes.
   • Drive two 2" screws into each rail-end contact.

6. Fit the raised bottoms

   Glue and screw the raised bottoms into the three module bases.

   • Spread glue on the rail tops and bottom-to-side contacts.
   • Seat each bottom between its side panels.
   • Clamp the bottom firmly against the rails.
   • Drill clearance and pilot holes through the marked side positions.
   • Drive the 2" screws into the bottom edges.

7. Fit shelves and solid landing

   Retain the two large litter tiers and the solid center landing without a hatch.

   • Mark side shelf undersides at 23 1/4", 41 1/2" and 42 1/2" above the floor.
   • Mark the solid center landing underside at its retained 18" height.
   • Spread glue on the solid shelf-end contacts.
   • Clamp each shelf level on temporary supports.
   • Drill the marked clearance and pilot holes.
   • Drive the 2" side screws into the shelf edges.

8. Fit the lower litter shelves

   Install the two retained low litter shelves at their original height for the proposed boxes and rear approaches.

   • Mark each lower litter shelf underside 5" above the floor.
   • Spread glue on the solid shelf-to-side contacts.
   • Clamp each shelf on temporary 3/4" spacers above the raised bottom.
   • Mark screw centers 2 1/2", 7" and 22 1/2" behind each side front.
   • Drill clearance and pilot holes at the marked positions.
   • Drive three 2" screws through each side into the shelf edge.

9. Fit the center access step

   Retain the lower center step beneath the solid landing.

   • Mark the step underside 10" above the floor.
   • Spread glue on the step-end contacts.
   • Clamp the step flush with the cabinet front.
   • Drill the marked clearance and pilot holes.
   • Drive three 2" screws through each side into the step.

10. Add the upper landing step

    Install the retained solid rear step level with both upper litter platforms.

    • Mark the step underside 23 1/4" above the floor.
    • Spread glue on the solid step-end contacts.
    • Clamp the step flush with the cabinet rear edges.
    • Mark screw centers 20", 24" and 28" behind each side front.
    • Drill clearance and pilot holes through the solid strips between passages.
    • Drive three 2" screws through each center side into the step.

11. Join the open-back modules

    Join the three square modules without adding cabinet back panels.

    • Stand the modules together with the narrow center cabinet between them.
    • Align the front and rear edges with a straightedge.
    • Clamp the adjacent side panels together.
    • Check the diagonals before fastening.
    • Drill the marked clearance and pilot holes.
    • Drive the 1 1/4" screws through the paired sides.

12. Fasten the continuous top

    Fasten the continuous top from below through all six retained concealed cleats.

    • Center the top across the joined modules.
    • Align its rear edge flush with the cabinet rear edges.
    • Clamp the top to the cleats.
    • Drill upward pilot holes with a depth stop.
    • Drive the 1 1/4" screws upward through every cleat.

13. Cover the exposed top edges

    Glue and pin screen molding over the front and side plywood edges.

    • Dry-fit the three edging pieces against the top.
    • Shave any open miter with the guided hand saw.
    • Spread a thin glue film on the mating edges.
    • Clamp the edging flush with the display surface.
    • Pin the edging with a hammer and nail set.

14. Seal the cabinet surfaces

    Fill, sand, prime and paint all cabinet surfaces and both faces of every full-height door.

    • Fill the brad holes and visible fastener recesses.
    • Caulk fine seams at the fixed top edging.
    • Sand the pine and plywood with 180-grit paper.
    • Remove all sanding dust.
    • Prime all faces and absorbent plywood edges.
    • Apply washable cabinet enamel according to its label.

15. Close the entire cabinet front

    Hang all six full-height doors to conceal every front compartment while retaining cleaning access.

    • Support each door on spacers with a 1/8" center gap.
    • Mark three hinge positions on every door.
    • Pilot the hinge holes with a stopped drill bit.
    • Fasten both hinge leaves with the pan-head screws.
    • Install the knobs with their supplied mounting screws.
    • Adjust the hinges until the doors swing freely.

16. Complete the site installation

    Approve television clearance, restraint, rear entry, ventilation and the internal cat route with the entire front closed before use.

    • Have an installer verify television clearance and the wall-door location.
    • Have the installer resolve baseboard interference and cabinet restraint.
    • Have the installer complete the site-specific house-door connection.
    • Place one lined box on each of the four litter platforms.
    • Reserve the rear 12" of each litter platform for cat access.
    • Test entry, exit and all four boxes under supervision with all six doors closed.