Entertainment Center

Materials:

table saw
3/4" and 1/4" plywood
circular saw
tape measure
chalk line
2x4 lumber
carpenter’s pencil
pneumatic nailer
1-1/2" finishing nails
wood glue
wood dowels
doweling jig
clamps
3/4" brads
1" screws
poplar wood (for face of top shelf)
miter saw
jigsaw
biscuit joiner
trim molding
220-grit sandpaper
palm sander
primer
paint
paintbrushes and nap roller
door hinges / doorknobs

Steps:

1. Using a table saw, rip the 3/4" plywood into 23-inch pieces for the top, bottom and the two sides. These pieces will form the frame of the unit.
2. Next, with a circular saw, cut two pieces of plywood to lengths of 47 inches for the top and bottom of the cabinet.
3. Then cut the two side pieces of the cabinet to 66 inches long. Make sure that the long edges of these pieces are straight.
4. Finally, cut five pieces of 2x4 to length. These will form the bottom frame of the entertainment center.
5. Next, begin assembling the frame. Measure in 6-1/2" on each side of the bottom and mark the location by drawing a line. Attach the two sides of the cabinet, applying glue and then nailing the pieces together with a pneumatic nailer loaded with finishing nails (figure A). Don't make more nail holes than necessary!
6. Repeat the same procedure to attach the top pieces, assembling the pieces at the marked locations and then glue and nail them together.
7. To complete the frame assembly, attach the 2x4 bottom frame with glue and nails (figure B).
8. Then fasten four heavy-duty top plates to the bottom and then screw on decorative feet to accentuate the unit.

Face Frame and Back

1. Attach the two side face frames, gluing and then nailing the pieces together.
2. Next, measure and cut the front face frame.
3. Mark the location for the dowel holes and then use a doweling jig to drill the holes. The jig keeps the holes aligned and the same depth in each piece.
4. Next, squeeze wood glue into each hole on one side of the frame and then drive in the wood dowels into the holes with a hammer. Then carefully align the wood dowels with the bored holes and press them into position (figure C) .
5. Next, clamp the frames together, check the assembly to make sure it is square, and set it aside to dry.
6. Once the unit is dry, position the front face frame so that the edges are flush and then attach them to the unit (figure D).
7. Finally, install the back--a piece of 1/4" plywood--and secure it with 3/4 " brads (figure E).

Attach Cleats

1. Begin by measuring for the length of the cleats to be attached to the unit. Using a circular saw, cut the cleats to length, then drill pilot holes into them.
2. Next, attach the cleats to the unit using glue and 1" screws (figure F).
3. Glue a strip of poplar to cover the face of the top shelf.
4. Add a center brace to the top shelf to help support the weight of a television set (figure G).

1. Take measurements for the drawer and transfer them to the 1x6 poplar. Using a miter saw, cut the four pieces for the front, back and sides of the drawer.
2. Next, cut the drawer bottom to size on the table saw. Use the table saw to cut 1/4-inch dado grooves into all four of the side pieces--these will be used to slide in the bottom of the drawer.
3. To create a pull for the drawer, lay out the area to be cut with a pencil and then use a jigsaw to make the cut.
4. Sand off the rough areas from all of the pieces of the drawer.
5. Use glue and 1-1/2" finishing nails to assemble three of the sides of the drawer.
6. Once the first three sides were joined, apply wood glue to dado grooves and slide the drawer bottom into place.
7. Attach the fourth side of the drawer using glue and finishing nails.
8. Attach slides to the interior of the cabinet and then attach the drawer to slides.

Build Shelves and Doors

1. Attach both of the shelves using glue and a pneumatic nailer.
2. Then take measurements for the door and transfer them to the 1x4 poplar and make the cuts.
3. Use a biscuit joiner to cut slots in the door pieces. To assemble the doors, place glue in the joints, insert the biscuits and clamp the pieces together to dry.
4. After the frame is dry, make router cuts inside the back of the frame and insert 1/4" plywood in the opening.
5. Cut molding pieces for the doors to size, mitering the ends and rounding the edges with a router. Glue and nail the trim molding in place.
6. Dry-fit the doors and measure for clearance. Install the bottom spacers inside the unit, attaching them with small finishing nails.
7. Finally, nail the top shelf to the spacers that will hold the television set.

1. Using 220-grit sandpaper, sand all the wood surfaces.
2. Next, make cutouts in the back of the unit so that cables and wires can be fed through. First, drill two holes, then use a jigsaw to cut out the area between the holes.
3. Then take measurements for the 1x2 poplar moldings for the top and bottom of the unit.
4. Next, position the top trim pieces flush with the top edge. Using a pneumatic nailer, attach the first piece of trim. Be sure to keep the overhang at 3/4". Next, attach the second piece of trim to the top of the cabinet. Lastly, nail the bottom trim piece in place, being careful to keep the trim flush with the edges.
5. Prime the unit and allow the primer to dry (figure H). Afterward, use a palm sander with 220-grit sandpaper to smooth all the wood surfaces and prepare it for the paint. The primer raises the wood grain so it's important to sand again to smooth out the surfaces.
6. Begin painting the unit, starting with the interior. Use a small roller to spread navy blue paint on the interior walls of the cabinet. Paint the shelves outside the unit instead of painting them attached.
7. After the first coat of blue paint has dried, apply a second coat. It is recommended that when painting in dark colors, you apply two or three coats.
8. Next, use white paint on the exterior, starting with a short-nap roller. Smooth out the paint with a trim brush, then apply white enamel paint to the exterior wood trim molding.
9. Lay the doors over sawhorses and paint them with brushes. After the topcoat dries, paint the other side of the doors.
10. Drill pilot holes in the doors, then attach the hinges using the supplied screws. Hold each door in place and attach the hinges to the cabinet with screws.
11. Next, mark the location for the doorknobs on each door and pre-drill holes for the hardware. Attach the doorknob, using the provided screw, and repeated the process on the other door.