This is a 12' floor to ceiling wall unit. It will house a TV and wardrobe. Normally this is a pretty straight forward project, but this one ended up pretty unusual in that its going to be installed in a second floor bedroom. Getting there is another issue due to a narrow stairway, then a sharp turn down a long hallway then another turn into the room. The unit is 8' tall, and so are the ceilings. The only way this is going to happen is by build components, then assembling them in the room once completed. Sounds easy enough, till the actual dissecting the unit, and where these components will be able to be joined so as not to look like a bunch of boxes slapped together, but tastefully done. The first unit will be the TV base unit. It will have 2 drawers at the bottom, with some open shelving, then the upper unit that will hold the TV and some additional open shelving for stereo and DVD equipment.
Doing something like this, fitting is critical so everything has to be square and true so it can be assembled on location without any problems. I use a jig like this one to keep the carcass square as I clamp
The next abutting cabinet will be some open shelving for collectibles. It will be only 12" wide, so I'll make that one complete unit. The shelving will be adjustable with pilaster standards that I've dadoed into the side panels to receive them later.
The next step is the bottom of the top section. To hide the separating joint, I'll have to notch for the stile then glue on an edge molding. To hide the plywood, I'll return the molding. All this will have to slide in on assembly to avoid detection of being a separate component.
Everything has to be made so it just slips in together like a glove, then secured with a few hidden screws. To do this, some sections won't have any stiles, but will slip behind another
Here are 3 sections completed. An end wing, the 12" tower, and the center base unit.
6 sections built, and two more to go. I've got one turned due to lack of room being so close to the ceiling and all that I have hanging in the way. By building bottom and tops, this allows the unit as close to the ceiling height without having to worry about tipping room to let into place. Then I'll just attach the crown molding to complete. The end wings will get raised panel doors, and the twin towers will remain open. Each base unit will have drawers.
Talk about just making it? Phew..........
Putting on the edge molding
I always transfer marks, rather than measure. It reduces room for error
Center unit complete, now I'll sand everything then start the doors
Man...... I've got just about every power tool I own out. Time to pick up
Now for the base molding. I played with a couple of cutters and came up with a nice combination. Its a little extra work, but it sure pays off in the end. I milled 2 separate pieces, and clamped them together
Really looks pretty impressive being built up this way
started milling the door parts and reading them for assembly. Before doors are assembled, I sand all the raised profile by hand with 150 grit, and the end grain with 220.
I back cut the backside of the raised panel, so that the panel sits flush with the face
Finally got the doors done up. These took a bit longer because I wanted to be sure the wood was well acclimated and dry due to the doors being extra tall at 56". This tall, doors will show the slightest bow or gap, so I don't like to risk rushing only to bring on disaster later. These doors came out dead flat! That duel Grizzly drum sander should be in every shop. The duel sander, is just so much better, especially when flattening stock and assembled doors, such as these.
Thought I'd place a few doors in temporarily, to get a perspective......... but the picture just doesn't do it justice. This unit is awesome in real time!
WARNING!!!!!!!!!!!!!!
Do not ever stand on a 1 gal. paint can trying to reach for something! They don't make them like they use to, and the can walls will crush, sending you quickly to the floor!!!!!!!! That isn't too bad except............ when a 250 lb sander follows you and pins you to the floor under it, its a whole other story! I'm pretty banged up and looks like today is wasted!
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