Pictured is one of a set of TV trays I made for my wife. Most sets contain four trays. She wanted six.
Materials required are--
1/2 inch A-D grade fir plywood
Plastic countertop laminate
Plastic laminate adhesive
Good hardwood of your choice for legs and trim
Aluminum bar stock
Wood and sheetmetal screws
Varnish or shellac
Tools required are--
A tablesaw or a radial arm saw
A router with a corner rounding bit and a laminate trimming bit
A bandsaw or a sabre saw.
A chisel for scraping
Screwdrivers (straight and offset straight)
An inexpensive paint brush for applying laminate adhesive
A hammer and a wood block
Step 1: Making the tray top
Commercially available TV trays always seem a little small to be really useful in my estimation. I made these TV trays 16 1/4 inches by 22 1/2 inches (finished) on top. This provides a nice working surface for more than just eating in front of the television. My wife does all manner of projects on them.
Begin by cutting pieces of 1/2 inch plywood 14 3/4 inches by 21 inches, one piece for each TV tray you want to make. Some solid wood trim will bring the tops up to the dimensions mentioned in the paragraph above, but that is for a later step. The edges of the plywood should be smooth. There should be no splintering or kicking up of the grain on the top "A" surface of the plywood. I chose to have the "A" side up so the plastic laminate would be glued to a nice smooth surface.