How to Make a Wooden TV Stand with a Barn Door Design
Building a TV stand with a barn door design is a rewarding woodworking project that adds both functionality and charm to your living room. This project involves using basic woodworking techniques, but it gives you the freedom to customize the design to suit your space. Whether you’re an experienced woodworker or a beginner looking for a fun DIY project, this guide will help you make a stylish and durable wooden TV stand with a rustic barn door design.
Materials and Tools You’ll Need
Materials:
- 2×4 lumber (for the frame and support)
- 1×6 or 1×8 boards (for the barn doors)
- Plywood (for the top, bottom, and shelves)
- Barn door hardware (track, rollers, and brackets)
- Wood screws
- Wood glue
- Wood stain or paint (optional)
- Sandpaper (for smoothing rough edges)
- Finish (polyurethane or varnish)
Tools:
- Circular saw or table saw
- Drill with various bits (for pilot holes and screws)
- Pocket hole jig (optional, but recommended for a cleaner finish)
- Measuring tape
- Clamps
- Wood filler (for holes or imperfections)
- Hammer
- Screwdriver
- Level
Step-by-Step Instructions
1. Plan Your Design
Before you start cutting any wood, take measurements of your TV and the space where the TV stand will go. This will help you determine the size of the stand. A typical TV stand is around 60 inches wide, but you can adjust the width based on your needs. Also, decide if you want shelves for storage, as this will impact the overall height and internal structure.
Sketch out the basic design of the TV stand, including the barn doors, which will be sliding across the front of the stand. Keep in mind that the barn door hardware requires some clearance, so plan accordingly.
2. Cut the Pieces
Using your saw, cut the following pieces:
Top, Bottom, and Shelves: Cut your plywood or 1x boards to the width and depth of your TV stand. For example, if you want a 60-inch wide stand with a 20-inch depth, cut the top and bottom pieces to 60 inches by 20 inches.
Frame: Cut the 2×4 lumber for the frame. You’ll need four vertical pieces for the corners and four horizontal pieces for the sides and middle shelves. If you want adjustable shelves, cut additional horizontal pieces to accommodate shelf brackets or pins.
Barn Doors: For the barn doors, you can use 1×6 or 1×8 boards. Cut two pieces to the desired height of your stand and width of your stand (typically, 30–40 inches tall and 25–30 inches wide). These will be the main panels of the barn doors.
3. Assemble the Frame
Begin assembling the main frame of the TV stand by attaching the vertical 2x4s to the horizontal ones. You can use wood screws to join these pieces together. For a stronger joint, consider using a pocket hole jig to create pocket holes for screws, which will give a cleaner and more professional finish.
- Start with the bottom frame and attach the sides to the front and back pieces.
- Next, attach the top frame.
- If you’re adding shelves, install horizontal supports inside the frame where the shelves will sit.
4. Install the Shelves
Once the frame is assembled, install the shelves. If you’re using fixed shelves, screw them directly into the frame. For adjustable shelves, drill holes for shelf pins along the vertical supports. This will allow you to change the height of the shelves as needed.
5. Attach the Back Panel
Cut a piece of plywood to the same size as the back of the stand and attach it with wood screws. This will help give the stand stability and prevent items from falling behind it.
6. Build the Barn Doors
To create the barn doors, lay out the 1×6 or 1×8 boards side by side, ensuring the edges are flush. Use wood glue to bond them together and secure them with clamps while they dry. Once the glue has dried, reinforce the door by attaching two horizontal battens across the back using wood screws or a nail gun.
You can add decorative elements to the barn doors, like a cross-frame design or handles. The cross design is a classic barn door style where two diagonal pieces of wood are attached in an “X” shape. If you want this, cut two diagonal pieces that cross in the center of the door and attach them with screws.
7. Sand and Finish
Before assembling everything, sand all the surfaces with medium to fine-grit sandpaper to ensure a smooth finish. Pay special attention to any rough spots, especially on the edges of the boards. After sanding, wipe down the wood to remove any dust.
Once sanded, you can finish the TV stand and barn doors with wood stain, paint, or clear finish, depending on the look you want. Apply the finish with a brush or cloth, following the manufacturer’s instructions.
8. Install the Barn Door Hardware
Now it’s time to install the barn door hardware. You will need a track, rollers, and brackets designed for sliding barn doors. Install the track securely on the top of the stand, making sure it’s level. The track should extend beyond the width of the doors so that the doors can slide completely open.
Attach the rollers to the top of the barn doors, then hang the doors on the track. Adjust the rollers to ensure the doors slide smoothly.
9. Final Touches
After the barn doors are installed, check to make sure they move freely along the track. Make any necessary adjustments to the rollers or track if there’s any resistance. You can also add rubber bumpers or felt pads to prevent damage to the stand when the doors close.
10. Install the TV Stand in Place
Finally, place the TV stand in your desired location. Position your TV on top and organize the storage below with any media equipment, DVDs, or gaming consoles. With the barn doors, you can easily hide away items when not in use, keeping the stand looking clean and tidy.
Conclusion
Building a wooden TV stand with a barn door design is a fun and functional project that can add character to your home decor. With a few basic tools, materials, and some patience, you can create a rustic yet modern piece of furniture that’s both practical and stylish. Whether you stain the wood for a natural look or paint it to match your existing decor, this barn door TV stand will be a conversation starter and a great addition to your living room.
For those who want to expand their woodworking skills, consider exploring Ted’s Woodworking Course for more detailed plans and step-by-step instructions on creating custom furniture and woodworking projects. Check it out here!