X-Door Rustic TV Console

by Adam Henley - ThePowerToolWebsite.com

20" (500) 59-1/2" (1488)

28" (700)
 Reference 1
Tools & Jigs
� Table Saw
� Track saw or Circular saw
(for breaking down ply)
� Table Saw Sled
� Vertical Cut Fence
� Pocket hole jig
� Brad Nailer
� Router (optional)
Cut List
* FF = Face Frame
X-Door Rustic TV Console
Hardware & Material
� [1] full sheet 3/4" (19) plywood
� [1] half sheet 3/4" (19) plywood
� [1] half sheet 1/4" (6) plywood
� [6] 3/4" x 8" x 8' (19 x 200 x 2400) board
� -----------
� 1-1/4" (30mm) pocket screws as needed
� 1-1/4" (30mm) brad nails as needed
� Wood glue as needed
� [4] door hinges
� [2] door knobs
� [16] shelf pins
� [2] magnetized door stops
� 1/4" (6) spiral router bit or straight cut bit
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Cutting Diagrams 1 X-Door Rustic TV Console

backstop

backstops

2
 Cutting Diagrams 2 X-Door Rustic TV Console

3/4" (19)

3/4" (19)

3
Cutting Diagrams 3 X-Door Rustic TV Console

1/4" (6)

4
 Exploded Views X-Door Rustic TV Console

C13 (X4)

C4
S6 C4
S5

S5

S6
C4
C4

C10

C8 S4
C9
S3
S4
C12
C9

C9
C10
C9
C7

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 Exploded Door X-Door Rustic TV Console

C5

S2

S7
S7

C6
C6

C5

6
 Top Detail X-Door Rustic TV Console

C13
C13
C13

C13

Edge glue and clamp the Top Boards (C13) together as shown.

7
 Upright Details X-Door Rustic TV Console

3/4"(19)
2"(50)
S5 (x2)

3/4"(19)

27-1/4" (681)

18" (450)
2"(50)

Pocket hole shelf pin hole

locations are approximate.
S6 (x2)

27-1/4" (681)

18" (450)

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 Frame Assembly X-Door Rustic TV Console

1
16" (400)
22" (550)
View from left
C4

C4

S6 S6
S5
C4
S5

C4

FRONT

View from right

C4

C4

S6
S6
S5
S5
C4

C4
FRONT

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 Bottom & Top X-Door Rustic TV Console

S4

S3
S4

3 1-1/4" (31) overhang

C13

10
 Side Trim X-Door Rustic TV Console

C10

C12

C11
FRONT
Flush

C10

C12

C11 BACK
Proud by
3/4" (19)

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 Back Trim & Face Frame X-Door Rustic TV Console

BACK
C1
5

C2

C8
6
FRONT

C9
C9

C9

C7

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 Shelves X-Door Rustic TV Console

S3

S4 S4

S3

C3

C3

C3

13
 Backing X-Door Rustic TV Console

S1

S1

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 Door Rails & Stiles X-Door Rustic TV Console

10 2-1/2" (63)

1/2" (13)

11a

11" (275)

1/4" (6)
C5
1/4" (6)

1/2" (13)
2-1/2" (63)

22-1/4" (556)

11b
C6 3/4" (19)

10" (250)

C5

1/2" (13)

11" (275)

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 Door Assembly X-Door Rustic TV Console

12

C6

C6

C5

C6
13
C6 S2

C5

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 Door Assembly 2 X-Door Rustic TV Console

C5

14 C6

C6
S2

C5

15
15" (375)

10" (250)

105°
37°

S7 S7
22-1/4" (556)

17-1/4" (431)

14
3°

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 Final Hardware X-Door Rustic TV Console

16
Magnetic door stop

Small wooden door stop

(3/4" x 3/4" x 2" block)
(19x19x50)

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 Assembly Instructions 1 X-Door Rustic TV Console

Pre Work

Assemble the Top

See page 'Top Details'.
If you're edge-gluing boards and building a regular panel, you can optionally reinforce it using biscuits, dowels, or
pocket hole joinery (in addition to edge-gluing each piece).

You can also incorporate breadboard ends, or you could use plywood for the top but be sure to add veneer
edge banding to cover the sides. If you use either of these alternative methods, adjust the material and cut list
as needed.

Prep the Uprights

See page 'Upright Details'.
Cut the notches in the corners as shown in the Upright Details page, on each S5. Add pocket holes as shown
(pocket holes should not be visible from the middle section of the console).

Drill the pin holes as shown for supporting the shelves later. You can also add the pin holes later in the
construction process if preferred.

Prep The Shelves

You can get veneer edge-banding to attach to the front edges of your shelves, so the plys are not exposed.

Alternatively, you can cut thin strips of wood and glue and brad nail them to the front edges of the shelves.
Or you can build the shelves from solid wood, each as a solid wood panel. Doing this will require some
changes to be made to your cut list and diagrams.

Main Assembly
Step 1 - Frame Assembly
Add the pocket holes to the ends of each C4, and to each Upright (S5 and S6) as shown.
Using pocket screws, assemble the pieces as shown.
Step 2 - Bottom
Glue 2 Side Shelves (S4) and one Mid Shelf (S3) down to the bottom stretchers (C4). You can use brads instead
of clamping if preferred.
Step 3 - Top
Position the top so there's 1-1/4"(31mm) overhang on the front, and both sides. There should only be 3/4"(19mm)
overhang on the back.
Secure the top (C13) to the uprights (S5 & S6) using 1-1/4" pocket screws.
Step 4 - Side Trim
Glue and brad nail the Side Rails (C10 & C11), and the Side Stiles (C12) to the assembly.
They should be flush with the front, and should overhang by 3/4" (19mm) in the back.
Step 5 - Back Trim
Glue and brad the Back Rails (C1 & C2) to the stretchers as shown.

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 Assembly Instructions 2 X-Door Rustic TV Console

Step 6 - Face Frame

Glue and brad the Top & Bottom Face Frame Rails (C7 & C8) the the stretchers as shown.
Glue and pocket screw the Face Frame Stiles (C9) to the uprights as shown.
The outer stiles should be flush with the outer edge of the side stiles.
The inner face frame stiles should be centered on the uprights.

Step 7 - Shelves
Insert the Shelves (S3 & S4) using shelf pins, where desired.

Step 8 - Shelf Backstops

Glue and clamp the Backstops (C3) to the back of each middle shelf (S3).

Step 9 - Backing
Glue and brad the Backing panels (S1) to the back of the side sections as shown.

Step 10 - Door Stiles

Mill the door frame stiles as shown, using your router with a 1/4" spiral or straight cut bit, or using your table saw.

Step 11a - Door Rails

Cut the edge groove in the door Rails (C5) using your router table or table saw.

Step 11b - Door Rails cont.

Cut the tongues on the edges of the Door Rails (C5) as shown, using your table saw sled and vertical cut fence.

Step 12 - Door Assembly

Glue the tongues of one Door Rail (C5) into the grooves of two Door Stiles (C6).

Step 13 - Door Assembly cont.

Immediately slide the Door Panel (S2) into the grooves until it seats in the groove on the bottom Rail. Note: The
panel is to be "floating" and should not be glued in place.

Step 14 - Door Assembly cont.

Now glue the tongues on the top Door Rail (C5) in the grooves of the Door Stiles (C6). Clamp the framed door
together at each Rail.

Step 15 - Door Assembly cont.

Once the glue has dried, cut the X pieces to fit in the door as shown.
Glue the X pieces to the door panel and set weights on it until the glue dries.

For a complete walk through on building framed "X" doors like this, visit this page.

Step 16 - Final Hardware

Now install your door knobs and hinges. Install a magnet door stop at the top inner corner of each door opening,
and a wooden block as a stop at the lower corner.

The magnetic door stop is something you can find at a hardware store and should come with a small metal plate
that screws to the door to work with the magnet.

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