'Ol Dave's Woodshop - Where woodworkers are not all Pros  

'Ol Dave's Woodshop - Where woodworkers are not all Pros
                                                                   "Where woodworkers are not all Pros"
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Grandson's TV Cabinet Project
Here's one for 'ya.  Taking orders from a sixteen year old!  A few months ago, my grandson (Austin) purchased a new wide flat screen TV for his bed room, which he had saved enough money for, and he placed the new TV on a folding table in his room.  Needless to say, after not too long of a time, the table started sagging in the middle.  The situation was only temporary since he planned on talking Grandpa into making him something better.  What might you say that his chances of being successful at doing that would be?  You guessed it...... and here he is with the finished project sitting in Ol' Dave's woodshop.
Austin and his completed TV stand.
Austin with stain trial boards.Austin had very specific ideas in mind as to what color he wanted to end up with.  He told me that he wanted a very dark color but not black and that he wanted to be able to see some "cool" wood grain.  We began with some red oak scrap pieces and started experimenting with stains.  After what seemed like about a dozen different stain trials (including black died wood using TransTint brand dye), we decided to just spray on three coats of dark walnut stain without wiping it off.  When we tried wiping off the walnut stain, the final appearance was not dark enough to suit him, hence the spray technique.  The photo on the right shows Austin with some of the stain trials that we made.
I must say, the final result looks really good but boy was it a bear to wait out the time that it took for unwiped stain to dry!  After getting Austin's approval of the color, we rounded up enough red oak to make the rest of the parts and began cutting!
I wanted to take the opportunity to teach Austin some of the things that goes into making a piece of furniture and at 16 years of age, I thought he would be able to help with some of them.  Since he was still in school when this project began, I tried to involve him whenever possible but being retired, I had more time than he had and he didn't get to help with all the things that needed to be done though.

Planing TV Stand legs
We began by cutting out the blanks for the four corner legs.  I used the same methods that I used on my Modified Shaker Style sideboard project.  After these pieces were cut, I took them to the jointer to get two of the sides flat and then to the planer to mill them to the final thickness needed (see photo on the left). 

I then showed Austin how to mark the leg pieces up for the mortises.  I used a 1/4 inch forstner bit to rough drill the waste material from the marked areas on the drill press and then how to chisel out the rest of the waste and square up the cavities (see photos below).

Austin chiseling out a mortise.
Grandpa helping Austin cutting mortises.
After the legs were completed, we cut out the face frame parts and the stiles & rails for the doors.  Some of the pictures of this process can be seen below.
This photo shows the stiles and rails for the door pieces laying on my workbench.
This photo shows another view of the door pieces on the bench.
Here you can see the contoured bottom piece of the face frame in the front vice of my bench.
Door stiles and rails for TV Stand.
Door Stiles & rails laying on workbench.
TV Stand Face Frame Bottom Rail

I didn't get any pictures of the upper and lower end panel rails as they were being cut but just so you know, they were made with tenons on the ends so that they would fit with the mortises in the legs.  I did get a couple of photos of the end panels as shown below with the one on the left showing both panels prior to inserting the end panels and the glue up.  The one on the right shows one of the panels after staining the insert panel and clamped up after gluing.
End panels rough fitted prior to glue up. End panel after inserting stained panel & showing clamping.

TV Stand Shelf with ironed on veneer.In the meantime, we made the shelves from red oak veneered plywood and I ironed red oak veneer on the edges of the finished panels as shown here on the right. This is a pretty simple process but the end results are really attractive after staining.  The main case panels were drilled for pins to support these shelves and can be seen in the photo below left.

TV Stand case after base coat staining.After the case was assembled and glued to the finished end panels, we gave the case a wiped on base coat prior to spraying on the final two coats of dark walnut stain.  We did this just to make sure that there was at least some color in the hard to get to places that might get missed during the spraying process.  The photo on the left shows the case after this was done.

Glued and clamped up TV Stand Top.
The next step was to cut and glue up the pieces for the top.  We used 5/4 red oak boards that were sent through the jointer to get good straight edges on them prior to the glue up.  After planing them to a uniform thickness, we glued them and clamped them and waited for them to dry (photo on the right).

Austin securing European style door hinges to doors.All that was left to do was spray on the stain and two coats of clear urethane finish and mount the doors to the case.  We used European hinges on the doors.  I used a 1 3/8" Forstner bit to make the pockets on the back sides of the doors to accept the hinges.  After the finish was applied, you can see Austin securing the hinges to the doors in the photo on the left.

I think this project was especially fun because I got to spend some time with my grandson building something that he shoud be able to enjoy for a long, long time!

As always, comments are welcome and you can get them to me by the e-mail address below.


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