How to build a 72" dark walnut-brown TV stand with concealed shelves

Cut list

Step by step

1. Shape scoops and edging

   Prepare the door scoops, cable holes and mitered oak borders before assembly.

   • Mark door scoops at their top centres with a 1/2" radius.
   • Clamp each front flat over scrap with the scoop beyond the bench edge.
   • Saw only the semicircles with a jigsaw and match door borders with a coping saw.
   • Drill the 2" back openings over a clamped sacrificial board.
   • Miter the edging with a backsaw in a clamped miter box.

2. Sand the visible surfaces

   Ease sharp edges and prepare the original oak for finishing and the internal shelves for use.

   • Sand the oak lightly with 180-grit paper along the grain.
   • Ease the scoop edges until they feel smooth.
   • Remove sanding dust with a clean cloth.
   • Label the hidden faces for assembly.

3. Assemble the recessed base

   Build the low recessed base on a flat surface.

   • Arrange the seven crosspieces between the two long rails.
   • Apply glue to each crosspiece end.
   • Clamp the rails square around the crosspieces.
   • Predrill and drive one 2" screw through each rail at every crosspiece.

4. Attach the cabinet bottom

   Fasten the bottom panel to the recessed base.

   • Centre the base beneath the bottom with its ends recessed 1 3/4".
   • Mark the crosspiece centres on the bottom panel.
   • Clamp the bottom against the base.
   • Drive two 1" screws into each crosspiece.

5. Fit the concealed cleats

   Attach the top cleats and restraint backing blocks while the uprights lie flat.

   • Lay each upright on a padded bench with its inside face upward.
   • Clamp each cleat flush with the upright's top edge.
   • Predrill three clearance holes through each cleat for the 2" screws.
   • Fasten the cleats from their free edges into the uprights.
   • Fasten the two backing blocks flush with the rear and top edges.

6. Assemble the cabinet bays

   Glue and screw the seven uprights onto the bottom panel.

   • Support the bottom on padded trestles with access underneath.
   • Mark the seven upright positions from the cut-list layout.
   • Apply glue to each upright's bottom edge.
   • Clamp the uprights square with equal-width spacer blocks.
   • Drive three 2" screws upward through the bottom into each upright.

7. Divide the open bay

   Fit the fixed shelf in the second bay from the left.

   • Support the shelf on two equal-height spacer blocks.
   • Apply glue to the shelf ends.
   • Clamp the shelf flush with the divider fronts.
   • Drive three 2" screws through each divider into the shelf edge.

8. Fit shelves behind the doors

   Install a fixed mid-height shelf behind each of the five existing doors.

   • Mark the shelf undersides level with the open cubby's shelf underside.
   • Fasten each support cleat with three 1 1/4" screws through pilot holes.
   • Set each shelf with its bare front edge 1 1/2" behind the finished cabinet front.
   • Drive two 1" screws upward through each cleat into the shelf.
   • Glue the plain oak edging flush with each shelf top.
   • Pin each edge with four 3/4" brads through pilot holes.

9. Square and attach the back

   Use the full back panel to square and brace the cabinet.

   • Place the cabinet face down on padded supports with a helper.
   • Adjust the cabinet until its diagonal measurements match.
   • Clamp the back flush with the bottom and side edges.
   • Fasten the back with the marked 1" screws.
   • Return the cabinet upright with a helper.

10. Fasten the thin slab top

    Secure the top from underneath without piercing its visible surface.

    • Position the top flush with the bare carcass sides and front.
    • Clamp the top firmly against every upright.
    • Predrill the top through the cleats with a depth stop.
    • Drive two 1" screws upward through each cleat.

11. Apply the flat oak borders

    Cover exposed plywood edges and add the doors' narrow flat perimeter borders.

    • Dry-fit the oak edging and each door's four border pieces.
    • Shave any gapped miter with a sharp chisel.
    • Apply glue to the edging and vertical door borders.
    • Glue only the centre of each horizontal solid-door border.
    • Pin the borders with 3/4" brads through predrilled holes.

12. Match the dark brown grain

    Finish all visible oak in a sampled dark walnut brown with a compatible clear coat.

    • Fill the brad holes with colour-matched wood filler.
    • Sand away glue residue without thinning the veneer.
    • Test the dark walnut brown stain on matching scrap.
    • Apply the approved stain sample colour to all visible oak.
    • Apply compatible clear coats after the stain has dried.
    • Allow the finish to cure fully before fitting hardware.

13. Hang the five inset doors

    Install two concealed no-bore hinges per door and adjust the inset reveals.

    • Mark hinge centres 3 1/2" from each door end.
    • Position the no-bore hinges using the supplied inset-door template.
    • Pilot the mounting holes with a depth stop.
    • Fasten each hinge with three pan-head screws per leaf.
    • Adjust the doors for approximately 1/8" clearance on every edge.
    • Test every finger scoop and the full opening swing.

14. Check the concealed shelves

    Verify shelf security and door clearance in all five closed bays.

    • Open each cabinet door fully.
    • Check all five shelves for secure seating.
    • Close each door gently against its hinges.
    • Check the rear cable openings for unobstructed access.

15. Restrain and check the cabinet

    Secure the cabinet against tipping and confirm the television and equipment fit before use.

    • Position the cabinet on a level floor without rocking.
    • Pilot the cabinet restraint plates through the back into the solid blocks.
    • Fasten each cabinet plate with two 3/4" pan-head screws.
    • Have a competent installer secure both restraints to verified wall structure.
    • Check television support spacing and equipment ventilation before loading.
    • Route cables through the rounded back openings without pinching them.