DIY AV Stand

Cutting the Parts

• 1

  Put on your safety goggles. Divide your plywood sheets into two 2-by-4-foot rectangles each with a pencil line. Use the L-square and straight edge to make sure the lines are perpendicular to the edges and perfectly straight. Two sheets are the top and bottom; the others will make up the shelves of the unit.

• 2

  Center the pencil line on the table saw blade. Cut the plywood sheets along the pencil line on the table saw.

• 3

  Mark off 4-inch squares on the shelves' corners with your pencil. Use the L-square to ensure perfect right angles. Using the straight edge as a jig, cut out the squares with the jigsaw.

• 4

  Make pencil marks along the 4-by-4-inch lumbers at 2-foot intervals. Cut them on the table into 2-foot lengths.

Assembling the AV Stand

• 5

  Make pencil marks on the 2-foot lengths at 8 and 16 inches. Draw pencil lines across the widths of these pieces at the pencil marks. Use the L-square to ensure the lines are perpendicular to the edges.

• 6

  Center the L-brackets on these lines so their free arms can support the shelves. Attach each L-bracket by driving two 3/4-inch screws through the bracket holes into the lumber.

• 7

  Attach the 4-by-4 lumbers to the top shelf by driving two 3/4-inch screws through the holes of the lower L-brackets' free arms into the shelf bottom. Turn the shelf and lumbers over so the lower L-brackets and shelf are at the bottom. Place the other shelf onto the upper L-brackets. Attach the shelf to the brackets with 3/4-inch wood screws.

• 8

  Attach the AV stand's top to the 4-by-4 lumbers by driving a 2-inch wood screw through each corner into the lumbers' top ends. Turn the piece over so the stand's top rests on your work surface. Attack the bottom to the stand with a 2-inch wood screw in each corner.

Sanding and Finishing

• 9

  Sand all surfaces thoroughly with the 1/3-sheet sander. Use coarse-grain sandpaper first, then medium-grain, then fine-grain paper. Wipe off all sawdust with the shop rags between passes. All surfaces should be glass-smooth after the last pass.

• 10

  Apply a coat of wood stain with a piece of cheesecloth. Let the stain dry completely. Sand off the raised fibers with fine-grain sandpaper.

• 11

  Apply a second coat of wood stain. Wait until the stain has dried completely. Brush on a coat of lacquer wood finish.