Originally Posted by DaveOP
Wow man, that looks awesome indeed. I have been really contemplating replacing my stand, as I have recently wall mounted the LCD, and I would really like more breathing room for the Onkyo, and a nicer setup for my consoles in general. I may try making my own after seeing that. How much did it end up costing you, if you don't mind me asking?
It's been an adventure to say the least. Most of the stuff (using a circular saw, using wood glue, etc) I did for the first time, sad to say (I'm a city boy, what can I say). But basically it came down to using the crap out of two things: a drywall square and a regular square.
It's just a lot of planning out on paper and math.
In terms of cost, for materials it was: 2 sheets of birch plywood 4'x8' ($59.99 ea), 32 x L-Bracket/Brace ($.97 ea), Wood Glue ($6.98), Screws #10 x 2 Box of 100 ($3.49), Screws #8 x 1/2 3 boxes of 100 ($10.47). I just bought a pack of 60 grit and a box of 150 grit sandpaper ($6.98 for both). I want to smooth out the edges quite a bit. 150 grit to sand before priming. Then I'll have to go pick up primer, black semi-gloss paint (the wife just said she think that'd be around $30) and 220 grit sandpaper for between primer and the coats and 320-grit for between the two paint coats...(Another $40 tops around).
So grand total of roughly $220, $120 of it being the wood itself (55% of the cost). You of course may have some of this stuff lying around (like the sandpaper, screws etc) or be able to get it for cheaper. I live 2 blocks from a Home Depot, so I just grabbed it there.
So basically, $220 for a custom built TV stand that will last a life time. I figured decent price. Plus you can never replace a sense of accomplishment and knowing you added something personally to your HT.
Now I didn't have all the tools as previously mentioned. I own and have used a mitre saw before (making a retaining wall in our yard) but that is all. So I ended up buying: circular saw ($70, comes with a laser guide), 4 C-Clamps ($5-10), 6' carpenter's level ($18), drywall square ($10 I think), regular square ($8), 2 sawhorse ($40), 2 36" x 3" gluing clamps ($25 each), and a sander ($70). A lot, but also all re-usable, and after having had success with the TV stand, I can foresee myself making other things, as I had a lot of fun. So though I had to buy a lot of this stuff, I did not see them as part of the cost for the TV stand, as I eventually would have bought all this stuff and everything can be used multiple times for any project.
In terms of how, I can send you a PM in detail if you like. I took pics of the steps here and there. You of course can change dimensions or style according to what your needs are. The two things I built around were the 6t6-MTM and the Onkyo 805. The 6T6 determined the height of the middle and right-side top and bottom cabinets (9"). It also determined the width of the middle cabinets only (23"). The width of right and left-side are 19", determined by the 805 and the fact that almost any normal component is roughly 17" wide (wanted an inch breathe room on the sides). I left the receiver's top wide open (it has about 13" above it). Depth of all shelves was determined by the depth of the Onkyo as it is the deepest component (19"). I am leaving it with no backing, as I like the airflow. This was based off my current stand that has no backing either. The shelves are recessed 3/4" in front and back from the supports, and the supports are recessed 3/4" in front and back and 1 1/2" on right and left sides from the top piece.
Overall dimensions: 65" wide, 22" tall, 23" deep.
I used 2 x L-brackets that used 8 x #8 x 1/2" screws each at every joint. Every joint was glued and then had 3 x #10 x 2" screws drilled into the joint perpendicularly. Needless to say it is a beast, but that's the way I like it. Some may say overkill, but I'm not an Ikea type of guy, I wanted it to be built tough.
I was able to lay over 400 lbs of weights from my home gym across the top without it even flinching (when I needed weight to press the top on the supports when gluing). And as for the shelves, I put over 100 lbs on the receiver's shelf and it didn't even budge, it was child's play to it.
Let me know if you want the gist of what I did and then you can take that and run with it and make it your own. I'll PM you no probs (got nothing important to do today, I'll just be sanding it today...)