Discovery JAK: TV Stand - Giving it a try...

My wife had been asking me for a while to try out a TV Stand from the Craftsman Drive website. After reviewing the plans and the part list I went to the Home Depot and picked everything up.

Luckily I brought my (sedan) truck along and was able to fit it all in...barely...HA!

As a quick side note, from what I could tell, the following are the GRK screws that were listed on the supply list from the site where I got the plans from.

I tried using structural screws for the pocket holes but found out that the head of the screws were too large in diameter to fit so I ended up just using the Trim Head Screws. Best I could tell I got the wrong screws. I was able to use them in a few places later on but had to get creative.

I started out by cutting 4 legs and 2 cross pieces from the 2x4s at 32 inches and 17 inches respectively.

I predrilled the ends of the 32-inch legs and used the trim screws to attach them to the 17-inch cross pieces.

I then cut two 2x4s to 69 inches and attached them to the two sets of legs with pocket holes and the trim screws.

I then attached the first shelf made of the 2x2s and 1x8s.

I then flipped the table over so I could add the shelf supports. No pocket holes on this one. I just used short screws and screwed it into the bottom of the shelf.

Next was adding the supports to the top of the table. After drilling the pocket holes in the two 2x4 supports I used two thin boards and my claps to hold the support in place. I put the pocket holes towards the top so that when I put the douglas fir on top you wouldn't be able to see the holes.

And finally...the top 2x8s were secured into place.

Time for sanding. I am pretty sensitive to dust so for extra protection I got myself a respirator and some filters from Amazon. The great thing with this respirator is that you can interchange with all types of filters for different types of projects. I didn't take pictures of all of the sanding but I did take a few pictures of how I finished the legs. I beveled the edges to keep it from splintering later. I liked how it turned out.

After further contemplation, I decided the table wasn't secure enough to hold up under the number of kids we had in our house. I was pretty sure that if my 4-year-old climbed onto the shelves that they would break. I decided to add two additional 1x3 braces for each shelf. I also added to more 2x4s to each side of the center of the table. It helped a lot. It still was 100% secure but it was much better and I was confident it would hold up to possibly being used as a playground. LOL

Ah, looking good. I brought it in the garage (door open) to stain and coat with polyacrylic.

I have used the MiniWax Weathered Oak stain on several projects now and really like it a lot. There is some grey color paint added to it that gives it the weathered look. Just make sure if you try it to use a paint mixer to get the paint off the bottom as it tends to settle under the stain.

After the second coat of poly I brought the table in and added some protective pads to keep the table from scratching the flooring. I put two on each leg for good measure...this table is super heavy.