Before construction begins, a cabinet should be designed to fit the size and needs of the space. Our application provided a niche that is 45" deep, 89-1/2" wide, and 83-1/2" high. The cabinet will be only 23-7/8" deep, 85-1/2" high. wide x 82- 1/4". The space left around the cabinet will be covered with molding in the final installation. It is essential to measure the equipment that will be housed in the cabinet and design the cabinet accordingly.
With the design finished, the next step is to cut the 4x8 plywood sheets to the depth of the cabinet. In our case, that dimension is 23-7/8". Each sheet will produce two 8" long panels.
Using a circular saw, cut the panels to the required lengths. This includes:Side panels (two measuring 45" long, 2 at 32" long); center vertical panels (one 45" and one 32"); 85-1/2" top, center and bottom panels and seven 30" shelves.
To create holes for the adjustable shelves, attach a dowel piece to the inside of each side panel that houses the adjustable shelves. By drilling through the pegboard (which features pre-drilled holes 1" apart), in every other hole, the shelves will have perfectly spaced holes 2" apart.
Sand all exposed surfaces with 220-grit sandpaper in a circular motion.
Begin assembly by drilling countersunk pilot holes for each of the screws. Position the countersink so the bit goes through the panel and the countersink makes a hole deep enough for the screw head.
Holes should be drilled through each of the side panels 3/8" from each end of the panel and should be approximately 10" apart.
When holes are drilled, arrange pieces and begin assembly by adding glue to the end of each 85-1/2" shelf. Align panels and drive 2-1/4" deck screws into each pre-drilled hole.
To raise the unit off the floor and allow space for the base trim, a 4" high base is attached to the bottom side of the cabinet. This base is a rectangular frame equal to the dimension of the bottom shelf and must be constructed with 1 " solid wood.
Next, spot the entertainment center. Do this with a soft cloth and rub the stain into the wood following the direction of the grain. Allow 6-12 hours for the stain to dry completely before handling the wood.
While the stain dries, cut the face molding to size. Front trim covers the front edge of all shelves and vertical panels. This hides the edge of the plywood and adds strength to the shelves. Attach face trim with 1" finish nails and patch with wood filler.
Back panel is manufactured from 1/4" stain-grade plywood. Cut 4x8 sheets to base unit size (32" x 85-1/2"). Stain and nail with 1-inch finish nails. "
The back panel for the top is made by cutting three panels 30" wide by 45" tall. Stain.
A slider for the rear panels at the top is made by cutting two - 1" x 2" to 85-1/2" long. A slot is cut into the 1" edge using a table saw. The depth of the groove on the upper rack should be 1/2" and 3/4" on the lower guide.
Attach the slide rails to the back, top, and bottom of the upper unit with the 2-1/4" deck screws. Insert the back panel into the top slot first, then the bottom slot. Slide the cabinet into its position.
Move the base unit into place leaving an equal distance on each side for the trim. Place the top on top and screw the halves together with 1" screws.
Measure for the colonial trim and base, and cut both to length. Fasten with 1" finish nails and patch all nail holes with paint putty.
