flat-screen

tv lift cabinet

2013 August Home Publishing Co.

Heirloom Project

flat-screen
TV Lift Cabinet
Now you see it, now you dont. This stylish and practical cabinet
allows you to have your flat-screen TV visible only when necessary.
Todays large, flat-screen TVs are And when you want to make the shelving, and open cubbies offers
certainly not unattractive, but can TV disappear, presto, it descends a variety of options.
be a bit overwhelming when on to be hidden until needed again. If all this sounds complicated
permanent display. This cleverly But thats just half the story, or to build, dont be concerned.
designed cabinet offers a solu- I should say, half the project. The Barebones, yet solid, joinery and
tion that allows you to have your cabinet also provides space and a few simple design tricks make
cake and eat it too. The secret is storage for all the gadgets and this project go together in a snap.
a smoothly operating lift mecha- accessories that enhance your And when its completed, the fun
nism that raises the TV out of the entertainment experience. A really begins. You might have the
back of the cabinet for viewing. combination of drawers, enclosed only levitating TV on the block.

1 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 Hinged lid on
upper case NOTE: Upper case
adds height needed
to accommodate
up to a 55" TV

OVERALL DIMENSIONS:
2814"D x 64"W x 3934"H NOTE: Plywood case
assembled with pocket
hole screws and
standard woodscrews
False drawer
This is front

Doors constructed
with offset
shoulder mortise
and tenon joints

NOTE: Plywood case

is overlayed with
hardwood framing

NOTE: Back of
case open
for easy access

Full-extension
drawer slide

S: Frosted glass obscures

wood
ain contents while still
wn) allowing remote use Filler blocks
reinforce feet
NOTE: Drawers joined
with lipped locking
rabbets at front and
tongue and dado at back NOTE: Easy cord
access is provided
throughout case

NOTE: For sources of

supplies and finishing
information, see page 15

is
SIDE SECTION VIEW
Rollers on
lift raise lid
as TV rises

NOTE: Front section

of case provides
abundant storage

NOTE: Lift installs

easily with screws

NOTE: Lift includes

both hard-wired
and wireless remotes

od
{ With the TV lowered, all you see is an attractive
storage cabinet. You might never guess whats
hidden in the rear compartment.

2 WoodsmithPlans.com WS20822 2013 August Home Publishing Co. All Rights Reserved.
 13#/4 57!/2 CASE
OVERALL DIMENSIONS: TOP/SHELF a. 1!/4" pocket
hole screw
17!/2 EDGING D
SHELF 20 8!/2
DIVIDER F
NOTE: This is
OVERALL DIMENSIONS: F
E A C
E
FRONT
SECTION B
Cutout VIEW
!/2
sized to fit C #8 x 1!/2" Fh
grommet 57!/2 13#/4 woodscrews
CASE
7 FALSE-BACK
Grommet
I b. SIDE SECTION VIEW
7!/2 H 13#/4
A G
OVERALL
26 DIMENSIONS: I D
CASE 1!/8
I A
SIDE F
17!/2 Case
F 1!/2
27!/4 E front
5 13 H HORIZONTAL edge
DIVIDER
ADJUSTABLE NOTE: This is
19!/2 A
I
Shelf pins SHELF 19 5
A
NOTE: This is
Center
CASE BOTTOM grommet
1!/2
B 20
25!/2 F
c. H
C
G D
57!/2
VERTICAL
25!/2 DIVIDER 6
Typical G
Plywood
I
endgrain
(#/4" shown) H d.
NOTE: This
NOTE: Shelfisand divider
edging is !/4"-thick hardwood. All !/4
!/16"
other parts are #/4" plywood C 7 chamfer

start with the Case

I
SIDE
SECTION
B VIEW
F
FRONT SECT. VIEW

Youll start by assembling the separated by shallow divid- Getting Started. The first pieces
large plywood case that forms the ers run across the top. Below, a youll need are the two sides, the
foundation of the cabinet.Typical
To keep centered bank of three drawers
Plywood bottom, and the false-back. Once
this task manageable, I reliedendgrain
on is flanked by enclosed shelving these are cut to size, you can start
Typical Plywood (#/4" shown)
endgrain standard woodscrews and pocket compartments. A section across drilling pilot holes.
(#/4" shown)hole screws for joinery. the back of the case is walled The case sides are fastened to
Overview. The deep case is off to hold the TV and lift. The the top and bottom with standard
divided into multiple compart- TV compartment isnt enclosed woodscrews. (Later, theyll be
OVERALL DIMENSIONS:
ments (drawing above). At the with a back panel just an open covered by solid-wood framing.)
front of the case, open cubbies frame. This allows easy access. So your first task is to drill a row
OVERALL DIMENSIONS: of countersunk pilot holes across

How-To: Divider & Shelf Cutouts

Typical Plywood the bottom of each side panel and
endgrain a second short series at the top. In
(#/4" shown)
addition, the side panels need a
pair of pocket screw holes on the
Template inside along the back of the top
edge. These are used to attach the
Flush-trim solid-wood top.
I bit
I Bottom. All the bottom needs
1!/2" for shelf divider is a series of countersunk pilot
5" for adjustable Waste
shelves
NOTE: This is a. END SECTION
VIEW
holes spaced along the length of
the panel near the middle. These
!/2" radius
will be used to fasten the false-
NOTE: This is Bearing back to the bottom.
Cut to waste rides on
side of template False-Back. The work on the false-
layout line
back takes longer. First, there are
!/2
pocket screw holes at each side
Band Saw. Lay out the shape, Trim. Next, I used a hardboard drilled from the back (detail a).
CUTOUT
TEMPLATE then remove the waste staying template and a flush-trim bit Next come several series of coun-
to the outside of the line. to smooth the cuts. tersunk pilot holes used to fasten

3 WoodsmithPlans.com WS20822 2013 August Home Publishing Co. All Rights Reserved.
 NOTE:OVERALL
This is DIMENSIONS:

the plywood top and internal How-To: Step-by-Step Assembly

panels. Finally, youll form three
cord access openings that are fit-
!/2"-thick cleat used to
ted with plastic grommets. position end panel
Cutting the access holes is the
only challenge and its a modest a. TOP
A VIEW
one. Flanges on the grommets B Cleat
cover the edges so the fit doesnt NOTE: This !/2 is
B
need to be perfect. Just lay out
Cleat A
the shape, drill starter holes, and
NOTE: This is A
B

remove the waste with a jig saw. Support block design

OVERALL DIMENSIONS: shown on page 13
Assembly. Once these tasks are
OVERALL DIMENSIONS:
completed, the sides, bottom, and
false-back can be assembled. The
trick is to keep the pieces aligned Side to Bottom. Start the assembly by clamping a cleat Opposite Side. The other
Typical
andPlywood
in tight contact while the flush with one side of the case bottom. Then clamp the side of the case can now be
endgrain
screws
(#/4" shown) are installed. The How-To case side to the cleat before installing the screws. attached in the same way.
box at right provides guidance.
Cleats and spacers are the key. NOTE: Case positioned Attach false-back to sides
face down with pocket hole D D
Cubby Assembly. Next, youll add screws CASE TOP
SHELF
the cubby assembly to the case.
This consists of a top panel, a E

shelf panel and a pair of dividers.

The top and shelf can be cut Woodscrews
used to
NOTE: This is
to identical size. The shelf needs attach sub-back Support NOTE: Back
NOTE: This is to case bottom
three pocket holes on the under- blocks edge of
OVERALL
Typical Plywood DIMENSIONS: dividers flush
IONS: 13#/4"-long spacer
endgrain
side at each end and then both flush with edges of
(#/4" shown) with back of
case bottom and ends top and shelf
panels have countersunk screw
Typical Plywood
OVERALLholes to fasten the dividers.
DIMENSIONS: endgrain Add the False-Back. Before installing the false-back, Assemble Cubbies. Clamp the shelf
The recessed (#/4" shown)
dividers have I clamped supports to the case sides and bottom, and dividers between the case top and
edging on the fronts. I also formed then turned the assembly onto its front. shelf, then install the screws.
cord cutouts on the back edges
using the technique shown on FIRST: Install Four spacers
screws 5" Spacer hold divider
Spacer
the previous page. Then you can inside through CASE TOP in position
assemble this OVERALL
section andDIMENSIONS:
add it case ends D

to the case as described at right. D Pocket hole

D
Lower Dividers. The final pieces to SHELF CASE TOP D
screws
install are a pair of vertical divid- SHELF
SECOND: 19!/4
ers and two horizontal dividers. Install NOTE: This is
OVERALL THIRD:
one atDIMENSIONS:
: This is screws through G
These are installed a time sub-back Install pocket
first the vertical dividers fol- screws through
shelf into ends
lowedNOTE:by the horizontal dividers. NOTE: Case is face up
This is
LL DIMENSIONS: Pocket hole screws hold the Add Cubbies. TypicalFlipPlywood
the case onto its back to install the Vertical Dividers. Spacers at the
Typical Plywood endgrain
verticalendgrain
dividers in place. Spacers cubby assembly. (#/4" Attach
shown) the top first. Spacers will hold top and bottom align the dividers
will help(#/4" keep
shown)them in position the shelf in place while driving the pocket screws. while installing pocket hole screws.
while installing the screws. Then
the horizontal dividers are added, Spacers
6 Spacers Template
NOTE: This is 5 C A tight against
also using pocket hole screws and
D sub-back
spacers (detail c, previous page). D
Shelves. You can wrap up this Template
G
phase by drilling sets of shelf pin H
H G flush with
holes in the side compartments 2 front of case
G G
NOTE: This is FIRST: Install H
and making four shelves. A tem- upper divider
G 4 5#/4
SECOND: Install
plate makes drilling shelf pin with pocket lower horizontal B
screws divider
holes go quickly (How-To box).
NOTE: This is
The shelves will need edging Finally, Horizontal Dividers. The horizontal dividers Shelf Pin Holes. Once the assem-
on the fronts and a cutout at the are likewise installed Typicalusing spacers. One set for the bly is completed, drill shelf pin holes
Plywood
ywood endgrain
ain
back (How-To, previous page). upper divider and a
(#/4" shown) for the lower divider.
wider set in both side compartments.
own)
4 Typical Plywood WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
endgrain
 NOTE: This is NOTE: Back rails are
1!/2" pocket 54 cut to fit between
hole screw J back stiles a.
M BACK RAIL !/2 Case side
NOTE: This is L
!/2 J K
FACE
FRAME 3
OVERALL DIMENSIONS: EDGING
Glue edging TOP SECTION VIEW
flush with
Drill #8 countersunk plywood
J screw holes from surfaces
BACK underside before b.
STILE installing top edging
K
3 1!/4
31!/4
L
J Top edge of
M bottom rail
J
NOTE: All parts are flush with top
OVERALL DIMENSIONS: made from #/4"-thick NOTE: Bottom rail
4 FRONT edge of case
hardwood STILE bottom
and all edging pieces
K are cut to fit
Lower edge FRONT
of rail aligns FRONT
BOTTOM RAIL VIEW
with top of !/2
taper on stile
NOTE: This is
Typical Plywood c. TOP SECTION VIEW
endgrain 1
(#/4" shown) J Case
M
d.
side 1#/4
FRONTTypical Plywood J 1!/4" pocket

adding the
STILE endgrain BACK hole screw
(#/4" shown) STILE 4 J
M TOP BACK BACK

Case Frames & Top

RAIL STILE
#/4
3
BACK VIEW
NOTE: This is

With the case assembled, you can
RALL DIMENSIONS:
now add the hardwood framing
that overlays it. The front comes
first, followed by the back, and
finally, the two sides. The fact
that most of the pieces are glued
in place with butt joints makes
this a fairly straightforward task.
Typical Plywood
Stiles. Since the front and back
endgrain
stiles are identical pairs, I started
(#/4" shown)
by making both at once. As you
can see in detail a, the outside
edges are rabbeted to capture the
NOTE: This is
edges of the side stiles. Further-
more, the lower ends of the stiles
are tapered to form feet.
Typical Plywood
Once the blanks are cut to size,
the box below leads you through
both operations. When the front
stiles are glued in place, the shoul-
ders of the rabbets should be flush
with the sides (detail c).
Rails & Edging. With the stiles in
place, you can fit the lower rail
and middle and upper edging
pieces and then glue them to the
case. The width of the middle
and upper rail should match the
thickness of the plywood. The
upper rail has countersunk screw
holes used later to fasten the
top. I used clamps with wedges
to apply pressure to the middle
piece. Finally, the edging for the
vertical and horizontal dividers
is added in the same way.
The Back Frame. The back frame
consists of just two stiles and an
upper and lower rail. However,
this frame is joined with pocket
hole screws, as shown above.
The two rails are identical in
size. But note that the upper rail
is installed proud of the ends of
the stiles (detail d). This exten-
sion fills a gap at the back of the
solid-wood top youll add later.
I sized the frame by clamp-
ing the two stiles in position on

How-To: Front & Back Stiles

endgrain the case and cutting the rails to
(#/4" shown)
fit between them. Then you can
assemble the frame with pocket
hole screws. Finally, glue and
J STILE
clamp the frame to the case, tak-
Aux. a. END VIEW
ing care to align it with the sides.
rip J side Frames. With the front and
fence !/2
back frames in place, fitting the
side frames is easy. Each consists
!/2 Cut to waste
#/4" dado side of layout of a pair of stiles and an upper
blade line and and lower rail. The stiles are cut
sand smooth
from stock planed to 12" thick,
Stile Rabbet. I used a dado blade buried in an Tapers. After laying out the taper while the rails are just 38" thick.
auxiliary rip fence to cut the 12" square rabbets in on each stile, remove the waste at After cutting the side stiles to
the front and back face frame stiles. the band saw and sand the edges. size and shaping the feet, the stiles
Typical Plywood
endgrain
(#/4" shown)
5 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 OVERALL DIMENSIONS:
16!/2 11#/4 CASE TOP
Q FRONT SECTION
O
5 a. VIEW
64
can be glued to the case (detail c). 28!/4 #/8
%/8
Thick cauls will provide a clamp- 1 Q20
ing surface on the interior of the
NOTE: case.
This Once
is all four side stiles are Pocket Case O
hole screws SIDE RAIL
O side 3
in place, the rails can be cut to fit
NOTE: This is
SIDE
between them and glued to the OVERALL N
DIMENSIONS: STILE 21
case flush with the upper and N
lower edges of the case sides. #8 x 1!/2" Fh
Foot Fillers. The tapered feet O
woodscrews
NOTE: Chamfer N b.
2!/4
are reinforced with filler blocks stile edges
NOTE: This is after all framing Case
glued up from three pieces of 34"- Rabbet fits
is attached side
over lower
thick stock (detail b). The box
OVERALL DIMENSIONS: edge of to case 31!/4 2!/2 O

below shows how theyre made. case side K 4!/2 P

P M
After smoothing the tapered
NOTE: Install top with N
faces, they can be glued in place. pocket hole screws P
J

Chamfers. The case needs one at back and standard FOOT

screws at front FILLER BOTTOM VIEW
more detail. All four corners are P O

chamfered to disguise the glue

NOTE: Case top is glued
line between the stiles. This is up from 1"-thick hardwood.NOTE: This is NOTE: Case top flush with c.
Case O
easy to do with a chamfer bit in a Stiles are !/2"-thick hardwood, back of case and centered side
and rails are #/8"-thick hardwood from side to side
hand-held router (How-To box). TOP 2#/4
OVERALL
Typical DIMENSIONS:
Plywood and two narrow extensions to Installation. Once its SECTION
endgrain VIEW
(#/4" shown) The Top size before gluing them together. ready, the top is fastened to N
Typical Plywood J
Adding a solid-wood top comes Bevels. To lighten the appear-
endgrain
the case with both glue and
!/4" chamfer !/2
next. And like the case it sits on, NOTE:
ance This
of the
is thick(#/4"
top, I beveled screws. I glued it to the case
shown)
the top has a large opening at the the lower edge of the front and top only through the mid-
back. The How-To box below sides (detail a). A simple router dle, used pocket hole screws at
shows how this opening is cre- jig and a straight bit will do the the back, and installed standard
ated. I simply cut a front panel job, as described Typical pagePlywood
onendgrain 13. screws through the front edging.
(#/4" shown)

How-To: Make the Filler Blocks & Top

NOTE: This is
: J Position filler
P blank with
Aux. rabbet over
fence a. END VIEW
Typical Plywood case side to
OVERALL
!/2 endgrain
DIMENSIONS: N
mark tapers
Aux. (#/4" shown)
Cut to waste
miter side of
fence #/4" P
#/4" dado ply. layout line
OVERALL DIMENSIONS:
blade
Case side

Typical Plywood
First, a Rabbet. Once the blocks areendgrain
cut to overall Mark Profile. With the rabbets cut, Cut the Tapers. Finally, cut the tapers
(#/4" shown)
size, cut a rabbet along one short edge. This allows you can position each block on the at the band saw and sand or plane the
the block to fit over the case side. case and mark for the taper cuts. faces before gluing the blocks in place.

NOTE: Top sections Extension NOTE: See page 13,

s are cut to Shop Notebook, for
a. final size, then details on building
glued together Front panel and using jig
J !/4 NOTE: Grain Backer
Wax NOTE: This is direction of Jig
paper Flush at ends board
Chamfer extensions matches
bit P that of front part
Typical Plywood END
N This is
NOTE:
endgrain VIEW TOP
(#/4" shown) Extension
Chamfer waste Q

Rout a Chamfer. Youll have to flip Three Sections. When gluing up the sections Edge Bevels. I used a router jig with a
the case onto its front and then its of the top, make sure that the outside edges are tilted fence to form the bevels on the front
back to rout chamfers on the stiles. flush and the panel ends up flat. and side edges of the top.

6 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 16 14 UPPER
UPPER
DRAWER DRAWER
BACK SIDE b.
a. S W Z T 16 S
V
UPPER !/4
DRAWER !/4" ply.
13!/2 U
#/8 X T
NOTE: This is 4&/8 FRONT
!/8
S
AA R

Horizontal !/4
MIDDLE NOTE: Fronts, sides, divider
!/4 DRAWER OVERALL DIMENSIONS: and back of
U SIDE U Front !/16" gap
individual drawers
W DRAWER X W identical in width face on all
BOTTOM MIDDLE edging sides
DRAWER BACK
NOTE: Drawers
#/8 vary in height
!/8 V dimension only.
U MIDDLE All other part
R
DRAWER dimensions
!%/16 V Y FRONT are identical
5&/8 Z
14" full- Y
Guide against TOP
back of front VIEW extension SIDE
U
drawer Y SECTION
slides LOWER VIEW
NOTE: Drawer fronts are LOWER DRAWER
#/4"-thick hardwood. DRAWER FRONT
Drawer backs and sides are U 6&/8
SIDE
!/2"-thick hardwood Z AA
NOTE: This is
LOWER c. Divider
DRAWER 17#/8
128mm Drawer
BACK S FRONT

constructing the
pull guide
Typical Plywood SECTION
endgrain NOTE: Drawer bottoms W
VIEW
(#/4" shown) are !/4" plywood 1!/2 U
1(/16 Z

Drawers & Doors !/16" Divider/Case

bottom

Building the three graduated rabbets that serve this purpose and back joints are different, you
drawers and a pair of doors will (detail a). The backs and sides can cut both concurrently, saving
complete the lower cabinet. I use tongue and dado joints. yourself some setup time.
OVERALL
tackled DIMENSIONS:
the drawers first. You can start by cutting the The first step is to form the lip
Drawer joinery. The drawers are fronts to size from 34"-thick stock and a tongue on the ends of all the
designed to fit flush with the and the sides and back from 12"- drawer fronts with a dado blade.
OVERALL DIMENSIONS: front edging and are installed thick stock. The drawers are sized Then after burying the same
in the case on metal slides. But for a 116" gap all around. dado blade in an auxiliary rip
rather than hide the slides with The box below shows the steps fence, you can form the tongues
S: OVERALL DIMENSIONS:
falseOVERALL
fronts, I DIMENSIONS:
joined the sides involved
Typical Plywood in cutting the drawer on the ends of the drawer backs.
and fronts with lipped locking endgrain
joinery. Even though the front You want both the front and back
(#/4" shown)

How-To: Lipped Locking Rabbets

NOTE: This is
Backer Aux. Rip
Tall fence
aux. R board Aux. fence T X
V Rip fence S W Z
fence Y AA
NOTE: This is fence
#/8" dado
blade R Y V Dado blade

s is
a.
NOTE: This is !/8 END Dado a. END VIEW a. END VIEW a. END VIEW
VIEW bladeNOTE: This is !/8
!/4 !/4 #/8

!%/16
!/8 !/4

A Slot. The first step is to cut A Tongue. Next, youll trim Back Tongue. Cut rabbets to Side Dadoes. Finally, use
a deep slot across both ends of back the inside shoulders to create the same size tongues a standard blade to cut
the drawer fronts. create 14"-long tongues. on the ends of the backs. mating dadoes in the sides.

7 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 CC
NOTE: This is
CC
14#/8 GLASS
tongues to be a saw blades width 5#/8 STOP
(18") in thickness. DD E E
12#/8 DD

Finally, I switched back to a #/16"-dia.

DOOR
STOP
standard
OVERALL blade to cut dadoes in
DIMENSIONS: 1!/4
through hole E E
for knob
the sides to hold the tongues. BB
22.5mm
The same setup will handle both BB
DD
13
dadoes on each side. OVERALL DIMENSIONS:
3 Concealed
MENSIONS: Before assembling the drawers, hinge
CC
youll have to cut grooves to fit the
35mm-dia. x 13mm-
plywood bottoms and cut the bot- deep hinge hole !/8"-thick
1!/4"-dia. frosted 15
toms to size. Then you can add the door glass
slides drawer section first, then a. TOP VIEW knob BB
Mortise 19#/8
the case section. The drawer sec- 1
tion fits tight to the front lip while !/4 !/4 NOTE: Door
rails and stiles
the case section sits back 14" from
ALL DIMENSIONS: BB #/8
!/4 are made from
2!/2 CC
the front facing (details a and c, #/4"-thick hardwood DOOR
CC
RAIL
previous page).
VERALL DIMENSIONS: NOTE:Adding
This is centered
Typical Plywood OVERALL DIMENSIONS: !/16" gap DOOR
pulls completes
endgrain the drawers. b. Mortise 1 c. around STILE BB
(#/4" shown) #/8 door
NOTE: This is
The Doors
OVERALL DIMENSIONS: BB
CC
d. Divider
DD
NOTE: This is Next up is a pair of glass-panel 2!/2 E E !/2
3 1#/4
SIDE
doors to enclose the side compart- BB SECT. #/4
ments. These are constructed with OVERALL DIMENSIONS: VIEW
#/8 CC
Door stops cut
offset-shoulder mortise and tenon to fit between
ONS: %/8 Door flush Knob case side and
joints, as in detail a. This creates 1 with face vertical divider
BACK VIEW frame
a ready-made pocket for the glass TOP VIEW
in the assembled frame.

How-To: Door Joinery

NOTE: This TheisSteps. Once youve cut the
stiles and rails to size, take a look
at theThis
NOTE: How-To
is box at right for a
NOTE: This is
step-by-step guideOVERALL through DIMENSIONS:
the
OVERALL DIMENSIONS:
joinery. As usual, cutting mor-
AA
tises in the stiles NOTE: is the
This first
is task. a.
OVERALL DIMENSIONS: BB
This is followed by rabbeting the Aux.
1
back, inside END VIEW
Typicaledges
Plywoodof both the a.
BB fence
#/16"isbrad
NOTE: This
stiles and the rails.
endgrain point bit #/8
OVERALL DIMENSIONS: (#/4" shown) Drill
This is Cutting the offset shoulder ten- overlapping END
holes to remove Aux.
Typical Plywood !/2
ons to fit the mortises in the rab- VIEW fenceendgrain #/4" dado
waste, then clean blade
ical Plywood beted stiles will be a test of your up with chisels to (#/4" shown)
endgrain !/4" mortise width
/4" shown) skill. Careful setup along with
test cuts are the keys to success. I Mortises. After laying out the mortises, drill Rabbets. The next step is to use a dado blade
cut the shorter inside cheeks first, out the waste with a series of overlapping buried in an auxiliary rip fence to cut rabbets
then reset the fence to cut the out- holes. Square up the mortises with chisels. on both the stiles and the rails.
side NOTE:
cheeks. The
This is
offset between NOTE: This is
the tenon shoulders should match
the depth of the rabbets.
Typical Plywood Aux. miter a. %/8
endgrain NOTE: This is END
Hinges & Stops. After the tenon fence CC
(#/4" shown) VIEW
FIRST: Cut Aux.
haunches
Typical Plywood are cut, the doors can inside CC !/4 fence
endgrain Typical Plywood
beshown)
(#/4" assembled
NOTE: Thisand is then installed cheeks
endgrain #/4" dado
with concealed hinges. And (#/4" shown) blade a. END
1 %/8 VIEW
finally, youTypical
can Plywood
add a pair of b. Dado blade
endgrain SECOND: Reset
stops to the case (#/4" (detail
shown) d). the fence and END
#/8
Glass. I waited until after the cut outside cheeks VIEW !/4
Typical Plywood
finish was applied to install the endgrain
wood glass with strips of 14"-square (#/4" shown)
ain stop. Its butt jointed and pinned Cheeks. Begin the tenons by adjusting the blade Haunch. The tenons are completed by
wn)
in place (detail c). A knob on height with test cuts. To avoid mistakes, I always holding the pieces on edge to cut the
each door is the last addition. set the rip fence to make the shorter cuts first. haunch on the outside edge of the stiles.

8 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 NOTE: UpperOVERALL DIMENSIONS: J J
FACE
case back, front, and F F FRAME
ends are made from #/4" plywood 54
54 54 EDGING a. 1!/2
HINGE RAIL I I L
I I
UPPER J J
#/4
CASE 5#/4
BACK F F
10!/4 HH
HH 6!/4
KK
6!/2 FRONT
UPPER SECTION
F F J J CASE
6!/2 6!/2 KK VIEW
UPPER CASE LID DRAWER
SIDE NOTE:
4&/8 This is FRONTS
STOPOVERALL DIMENSIONS: 17!/2 1!/2
GG
17#/8
UPPER CASE 3
FRONT NOTE: Hinge rail, lid stops, edging,
12!/2
and drawer fronts are made from b. HH
#/4"-thick hardwood
F F
NOTE: This is

c. SIDE SECTION !/16"-thick

constructing the
L
!/16"-thick spacer VIEW spacer
used to locate I I J J
drawer front

Upper Case
GG KK
HH
#/4 L KK !/2"-dia.
access
TOP SECTION VIEW hole

2 F F 2 GG
NOTE: This is
The shallow upper case is posi- Note that the back piece is nar- L

tioned over the gap in the case rower than the front and sides
top. This adds the height neces- (detail c). A recess created at
sary to accommodate a large TV. the top will be filled with a solid-
The step-back design allows a wood Typical hinge rail. And even though
Plywood to drill holes in the ends of the
lower viewing angle and makes theendgrain grain direction of the front and front and back (detail a).
(#/4" shown)
for a more pleasing appearance. back runs horizontally, you want Once all the pocket screw
The upper case is built as a the grain direction of the two
OVERALL DIMENSIONS:
holes were drilled and the case
four-sided plywood box with a sides to run vertically. assembled, I added a few auxil-
Typical Plywood
false drawer assembly applied to
endgrain Next comes a stint drilling mul- iary parts. As I mentioned, a 112"-
the (#/4"
front. A top with an integral tiple pocket screw holes. These
shown) wide hinge rail is fit across the
hinged lid allows the TV to rise will be used to fasten the parts back (detail c). Youll also need
from its compartment. to each other, the upper case to to install a pair of lid stops flush
Getting Started. The first thing to the lower case, and the top to the with the top edges of the sides.
do is assemble the plywood box. upper case. All but the back need False Fronts. The false drawer
This is accomplished with pocket holes on both the upper and lower assembly serves to disguise the
hole joinery. I began by cutting edges. The back has holes only on unique function of the upper
OVERALL DIMENSIONS:
all the pieces to size. the lower edge. Youll also need case. Its an easy addition.
Typical
OVERALL Plywood
DIMENSIONS:
endgrain

How-To: Make the Upper Case Top & Lid

(#/4" shown)
OVERALL DIMENSIONS:
NOTE: This is

NOTE: Start with a Cut to extension

Top extension side of layout Aux.
single oversized blank
NOTE: Lay out line fence
lid measuring 25&/8
Joint back edge from the Lay out Rip
before ripping Top extension fence
line
front rail free
25&/8
Lid Top front rail
MM
a. END VIEW
Lid
11#/4
NOTE: This is
Top extension NOTE: This is 2#/4
Top extension
NOTE: This is Top extension

Top front rail

Rip First. Joint the back edge of the Lay Out Lid. Next, lay out the Cut Lid. Now, trim the Rip Front Rail. Rip the
oversize panel and then rip the lid sec- final length of the lid through the lid to length with a single front rail to width before
tion to the width of the extensions. center of this section. cut on each line. reattaching the extensions.
Typical Plywood
9 WoodsmithPlans.com endgrain
WS20830 2013 August Home Publishing Co. All Rights Reserved.
(#/4" shown)
NSIONS:
L DIMENSIONS:

51#/4 MM
NOTE: Upper case lid
and top are cut UPPER a.
from oversized CASE L L MM
The first step is to frame in the 1"-thick panel LID
three openings with 34" square 11%/8
52 59 is F F HH
pieces. I fit and glued the short NOTE: This NOTE: Bevel
3!/2 on upper case FRONT
ends first, followed by the top and top identical SECTION 1!/4" pocket
11#/4 UPPER
bottom rail. Complete the job by CASE to that on VIEW hole screws
L L lower case
TOP
adding the two dividers. Theyre top
!/8" chamfer on
located to create equal openings. lid lower front
3"no-mortise and ends
The drawer fronts are cut from hinge with
3 "-thick stock and sized for a screws Case top Case
TE: ThisNOTE:
is 4
This is back rail
1 " gap all around. Before gluing
16 8
them to the case front, I drilled OVERALL DIMENSIONS:
pilot holes for the centered pulls
and also drilled larger corre-
sponding holes in the case front. b. MM 2#/4
These allow you to install the NOTE:
Upper case %/8
20
pulls after the fronts are glued on. attached to
lower case with
pocket screws F F
Top & Lid L L
Making the top with its hinged c. Cut mortise
SIDE
SECTION
GG
lid will complete the upper case. in hinge VIEW
rail only
Its assembled somewhat similar MM Typical Plywood
endgrain
to the lower case top, but with a Depth of mortise (#/4" shown)
twist. The How-To box starting equals hinge leaf
thickness
on the previous page shows how NOTE: This is I I
the top and lid can be cut from
a single panel to create a perfect
Plywood figure match across the assembly. top and lid are trimmed to exact the case before attaching it with
Typical Plywood
dgrain endgrain I started by gluing up and sur- size before both get a profile a pocket hole screws.
shown)
(#/4" shown)
facing a panel about 1" oversized routed bevel on the underside of The Lid. The lid is attached to
in width and 2" in length. After the top and chamfer on the under- the upper case with a pair of no-
jointing the back edge, you can side of the lid (details a and b). mortise hinges. But in order for
start cutting the panel into pieces OVERALL
Installation. Once the top and the lid to sit flush with the top, I
DIMENSIONS:
OVERALL DIMENSIONS:
as shown. In brief, youll rip the lid were completed, you can had to set the hinges in shallow
panel to create a lid/extension start adding the upper case to the mortises cut in the hinge rail, as
section and a front rail. Then lower case. First, clamp the case shown in detail c. I installed
after crosscutting the extensions over the rear opening and install the hinges in the mortises, then
from the lid, youll glue them back the pocket hole screws that hold attached the lid. Aim for an even
onto the front rail. Finally, the it in place. Then, clamp the top to gap all around.
OVERALL DIMENSIONS:

Top & Lid cont. Typical Plywood

endgrain MM
Aux. miter (#/4" shown)
NOTE: Be sure fence UPPER
extensions are L L CASE LID
square to top NOTE: This is
NOTE: This is Rip
front rail fence

Top 52 Trim top to length

extensions Top with equal extensions
14!/2 front
rail
a. END VIEW a. END VIEW
3!/2 11%/8

NOTE: This is

Wax paper

Glue Extensions. When gluing the exten- Trim Top to Length. Once the glue is Trim Lid to Final Width. To create a clear-
sions onto the rail, make sure the figure dry, trim the top to final length with an ance gap for the lid, youll need to trim 18"
aligns and the lid gap is accurate. equal extension at each end. from the front edge of the panel.

10 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 OVERALL DIMENSIONS: NOTE: Apply finish
to cabinet before
installing lift hardware a. TV mounted
slightly lower
Lift bracket than lift roller Case lid
Make sure lift fastened to
is installed back top rail
perfectly with #12 x #/4"
vertical Ph woodscrews

NOTE: Bracket
screws installed
OVERALL DIMENSIONS: before mounting
plate screws Back
top
Horizontal rails rail
attached to the
lift mechanism
NOTE: Control box Lift
Vertical rails NOTE: This is and power supply rails
on TV hook mounted to bottom
over horizontal of TV cabinet
rails 12 x #/4"Ph
woodscrews

b. Case lid Lift rollers

SIDE open lid as
Mounting plate TV is raised
centered in case with SECTION
upper bracket tight VIEW
against back top rail
TV
bracket

installing the
NOTE: This is
Case
bottom

Lift & TV
Lift base plate
SIDE SECTION
VIEW

The cabinet is now complete youll attach to the TV. Once the rollers (detail a). Then, when
except for a couple of very impor- parts are in place, the TV brackets everything is ready and you
tant components the TV and simply hook over the rails. The push the button, the cabinet lid
Typical Plywood
the lift that carries it. But these
endgrain TV should be positioned with the will slowly swing open and the
final steps are a piece of(#/4" shown)
cake. top edge slightly below the lifts TV will magically appear.
Before adding the lift and TV,
youll want to apply a finish to the
cabinet. And as you can see in the
photo at right, I stained and fin-
ished the TV compartment just
for the sake of tidiness.
Typical Plywood The Lift. The lift is installed in the
endgrain
(#/4" shown) cabinet before the TV is mounted
to it. The main drawing and
detail a show how the lift is
attached by means of a mounting
plate at the bottom and a rear fac-
ing bracket at the top.
First, I centered the lift side-
{ The TV lift to-side with the bracket tight
includes both against the upper frame rail. Then
a wireless I drilled pilot holes for the pan-
(above) and head screws and installed them.
a hard-wired Finally, I made sure the lift was
remote. perfectly vertical before install-
ing screws through the bottom
mounting plate.
The TV. Mounting the TV on the
lift is equally easy. The hardware
consists of a pair of horizontal { The open back of the case
rails that attach to the lift and allows easy installation of
a pair of vertical brackets that the lift mechanism.

11 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
Materials, Supplies, & Cutting Diagram
A Case Sides (2) 3 ply. - 251 x 271 #/4"x 7"- 72" Cherry (3.5 Bd. Ft.)
4 2 4
B Case Bottom (1) 34 ply. - 2512 x 5712 J J

C Case False-back (1) 3 ply. - 26 x 571 J J

4 2
D Case Top/Shelf (2) 3 4 ply. - 1334 x 5712
3 ply. - 81 x 5 #/4"x 7"- 72" Cherry (3.5 Bd. Ft.)
E Shelf Dividers (2) 4 2
P P P
3 M
F Edging (1) 4 x 14 - 96 rgh. P P P
3 ply. - 133 x 191
K
G Vertical Dividers (2) 4 4 2
NOTE: This is 3 F
H Horizontal Dividers (2) 4 ply. - 1334 x 1712 #/4"x 7"- 72" Cherry (3.5 Bd. Ft.)
I Adjustable Shelves (4) 3 ply. - 13 x 19 P P P
4 M
J Front/Back Stiles (4) 3 x 3 - 311 P P P
4 4
3 L
K Front Bottom Rail (1) 4 x 114 - 54
L Face Frame Edging (1) 3 x 3 - 340 rgh. #/4"x 7"- 72" Cherry (3.5 Bd. Ft.) EE
4 4
II
M Back Rails (2) 3 x 4 - 54 JJ JJ
4
N End Stiles (4) 12 x 234 - 3114 L
O End Rails (4) 3 x 3 - 21
8
#/4"x 7"- 72" Cherry (3.5 Bd. Ft.)
P Foot Fillers (4) 2 4 x 212 - 412
1
BB BB CC CC
Q Top (1) 1 x 2814 - 64 BB BB CC CC
R Upper Drawer Front (1) 3 4 x 478 - 1738
1 x 47 - 14 DD
S Upper Drawer Sides (2) 2 8 1"x 7"- 72" Cherry (Three boards @ 4.4 Bd. Ft. each)
T Upper Drawer Back (1) 1 2 x 478 - 16
Q Q
U Drawer Bottoms (3) 1 ply. x 131 - 16
4 2
V Middle Drawer Front (1) 3 x 57 - 173
4 8 8
1 x 57 - 14
1"x 7"- 72" Cherry (Three boards @ 4.4 Bd. Ft. each)
W Middle Drawer Sides (2) 2 8
X Middle Drawer 1 x 57 - 16 LL & MM
Typical Back (1)
Plywood 2 8 Q
Y Lower Drawer endgrain
Front (1) 3 x 67 - 173
4 8 8
(#/4" shown)
Z Lower Drawer Sides (2) 1 x 67 - 14
2 8 #/4"x 7"- 72" Cherry (3.5 Bd. Ft.)
AA Lower Drawer Back (1) 1 x 67 - 16
2 8
R
BB Door Stiles (4) 3 4 x 212 - 1938 Y V

CC Door Rails (4) 3 x 21 - 143

4 2 8
DD Glass Stop (1) 1 4 x 14 - 120 rgh. #/4"x 7"- 72" Cherry (3.5 Bd. Ft.)

EE Door Stops (2) 3 x 1 - 195

4 2 16 KK KK KK
FF Upper Case Sides (2) 3 4 ply. - 1212 x 612
GG Upper Case Front (1) 3 ply. - 61 x 54
4 2
!/2"x 7"- 72" Cherry (3.5 Sq. Ft.)
HH Upper Case Back (1) 3 ply. - 53 x 54
4 4
N N
II Hinge Rail (1) 3 x 11 - 54
4 2 N N
JJ Lid Stops (2) 3 x 11 - 101
4 2 4
KK Upper Case Dwr. Fronts (3) 34 x 478 - 173/8 !/2"x 7"- 60" Cherry (3.0 Sq. Ft.)
LL Upper Case Top (1) 1 x 1412 - 59 O O
MM Upper Case Lid (1) 1 x 1158 - 5134 O O

(1) TV Lift Mechanism !/2"x 7"- 60" Hard Maple (2.9 Sq. Ft.)

(2) 114" Dia. Knobs S S T

(6) 128mm Pulls
(3 pr.) 14" Full-Extension Slides
!/2"x 7"- 60" Hard Maple (2.9 Sq. Ft.)
(1 pr.) 3" No-Mortise Hinges
(12) #4 x 58" Hinge Screws W W X

(3) Access Grommets

(2 pr.) Euro-Style Inset Hinges !/2"x 7"- 60" Hard Maple (2.9 Sq. Ft.)
(16) 14" L-Style Shelf Supports
Z Z AA
(2) 13" x 15" Frosted Glass Panels
(41) #8 x 112" Fh Woodscrews
(79) 114" Pocket Hole Screws ALSO NEEDED: Two 48" x 96" Sheets of #/4" Cherry Plywood
One 48" x 48" Sheet of #/4" Cherry Plywood
(8) #12 x 34" Ph Woodscrews One 24" x 48" Sheet of !/4" Maple Plywood

12 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 tips from our shop

Beveling Jig
The design of the TV lift cabi-
net calls for a wide bevel on the
underside of the tops for the main
case and upper case. The size of
the assemblies means that cutting The Jig. The drawings below of the fence and depth of cut to
these bevels on the table saw isnt show how the jig goes together. be adjusted easily. A bit guard
practical. So to handle this job, I An auxiliary router base is and handle attached to the fence
put together the adjustable router attached to a large fence at a 70 make the jig more user friendly.
jig shown in the photo above. angle (the bevel angle is 20). The Cuts. The best way to create
The jig relies on a 112"-long, 12"- One side of the fence is fastened a smooth profile is with multiple
dia. straight bit to cut the bevels through a curved slot in the passes. The initial cuts can be
cleanly and manageably. base. This allows the position about 18" in depth. And as the
NOTE: Bit guard is made bevel lengthens with each set of
from #/4"-thick hardwood. passes, lighten up on the depth of
Fence is #/4" MDF. Auxiliary
base is !/4" hardboard 3#/4" wood drawer cut (details c and d).
4
OVERALL DIMENSIONS:10 pull with screws Start at the back right corner
Bit guard NOTE: Counterbore and move right to left around
Auxiliary holes for pull screws
base on bottom of fence the top. As you see in the photo
2!/2"-deep x 1"-
wide notch above, I clamped a backup piece
is centered behind the left end of the top. This
Fence
prevents tearout as the bit exits.
6 Center point
of !/4" slot arc c. END VIEW
10
7#/4" NOTE: Dimensions shown
radius for bit guard and Bit guard
OVERALL
3!/2 DIMENSIONS: fence are prior
DIMENSIONS: to assembly and Fence
#/4"-dia. beveling of edge
NOTE: This is Top
!/4" curved slot
1" fender
washer First few passes
b. FRONT VIEW made at !/8"
(router and auxiliary base) depth of cut
#8 x 1!/2" Rh
woodscrew

a. END SECTION VIEW d. END VIEW

Slot
Bit allows
guard fence to be
adjusted
Auxiliary
base Fence
NOTE: This is
NOTE: This is

NOTE: Glue fence

and bit guard Complete bevel
together, then with light
20 cut bevel skim passes

13 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 OVERALL DIMENSIONS:
OVERALL DIMENSIONS:

Panel Support Block 4 1

4 4
When assembling the lower case
of the TV lift cabinet, I needed a
NOTE: This is
way to hold the large plywood
panels upright and square to each
other while I installed the screws. Extra-long
(4"-wide),
Furthermore, I wanted to raise glued-up
MDF blank
the panels high enough to allow
clamps to be slipped underneath.
The slotted support blocks you
see at right are the answer. NOTE: This is
2
NOTE: This is
The square blocks are cut from
a long blank glued up from three #/4" dado
layers of 34" MDF. A dado blade blade
makes quick work of cutting two Make one
NOTE: Blocks #/4"-deep cut, turn
perpendicular slots in one face are made from 90 and repeat
(Figures 1 and 2). #/4" MDF

14 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.
 MAIL Project Sources
ORDER
SOURCES I found most of the hardware for the
TV lift cabinet at Lee Valley. Youll need
Woodsmith Store
800-444-7527 114" dia. knobs (02A17.70), 128mm
pulls (02A17.77), 14" drawer slides
Lee Valley (02K42.14), 3" no-mortise hinges
800-871-8158 (00H51.24), 58" hinge screws (01Z10.52),
leevalley.com
access grommets (00U09.91), and
Rockler inset hinges (00B15.34).
800-279-4441 The Whisper Lift II (23202) came
rockler.com from Touchstone. And Rockler carries
Touchstone the shelf supports (33860).
888-267-3615 The TV cabinet was stained with a
touchstonehome- mix of equal parts Varathane Gun-
products.com stock and Early American oil stains.
This was followed with two coats of
satin lacquer.

15 WoodsmithPlans.com WS20830 2013 August Home Publishing Co. All Rights Reserved.