Hi,

Here I document the creation of my TV stand for my living room! I needed a very specific size to fit right between a door and a cupboard and I couldn't find one, so I decided to make one!

In this instructable I will explain the process step by step and will provide some more instructions on how you can vary the design and add functionality.

Content:

1. Required supplies

2. Basic design

3. instructions for add-ons

If you have any feedback on how I can improve this instructable, let me know!

Supplies

Basic design:

Cement mix or concrete mortar
- Where to get: local hardware store
- Quantity: depends on the brand you buy as well as the size of the TV stand. More on this below
- For ease of use, choose one where you just have to add water
MDF or melamine panels
- Where to get: local hardware store or woodshed
- Quantity: depends on size of the TV stand. Check with your local hardware store how much you need.
Screws and kit
- Where to get: local hardware store
- Quantity: depends on the brand you buy as well as size of the TV stand. Ask your local hardware store for help on your design.
Metal mesh frame
- Where to get: local hardware store
- Quantity: depends on size of TV stand.
- A good indication of quantity is to use the same square meters as the walls of your mold, if you lay them out flat.
Large bucket or tub
- Where to get: local hardware store
- Quantity: 1 or 2
- get a big one (I used a 70 liter bucket) which you can reuse
Paint mixer or concrete mixer
- Where to get: local hardware store
- Quantity: 1
- If you have a good drill get a paint mixer, or opt for renting one at your local hardware store
Leveling cement or concrete fix
- Where to get: local hardware store
- how much: 1 package should be enough
Sanding paper
2x4s (2-3 meter / 6-9 foot)
length of square metal tube (16x16mm or 20x20mm | 5/8th x 5/8th inch or 25/32nd x 25/32nd inch)
- Where to get: local hardware store

Tools:

Powered drill
(Electric) screwdriver
Length of 2x4 (1m/3ft)
Caulking gun
Sanding machine
Shovel
(Mitre) saw
Hammer
Optional: vibrating concrete needle

Optional

Concrete pigment
- Where to get: larger hardware stores or online
- Quantity: depends on brand and size of tv stand. Please check instructions of the pigment
Cover panels and hardware (get them at Ikea)
drawer hardware (get them at Ikea)

Step 1: Design and Getting the Right Measures

Create your design by drawing it either on paper or using your preferred design software. Here, I used Sketchup.

Using your measurements you can calculate how much concrete mix you need as follows:

Length x width x thickness of each wall. In my case, I have four walls:
wall 1: 130cm x 34cm x 4cm = 17.7 litres
wall 2: 130cm x 34cm x 4cm = 17.7 litres
wall 3: (34-2x4)cm x 34cm x 4cm = 3.5 litres. I took out the edges to avoid double counting the volume.
wall 4: (34-2x4)cm x 34cm x 4cm = 3.5 litres
Total volume = 42.5 litres
Ask your local hardware store or check on the manufacturer's website how much bags you need for this volume. Make sure you have enough, this avoids you having to run back if you do not have enough :)

Step 2: Creating the Mold

After you're happy with your design, you can start on the mold.

For this build you will need to create an inn and outer bold, as well as a backpanel. Use your saw to get the MDF panels to size. Next, use your screwdriver and screw the panels together. Do this both for the inner and outer panel. Lastly, use the kit and caulking gun to seal all gaps between the panels.

Before fixing the inner and outer mold to the back panel, dry fit them to see if the design is to your liking. Next, connect the inner and outer panel to the back panel with screws and again use the caulking gun to seal all gaps.

Next, use the 2x4s to support long sections of the mold (such as the outside and inside of the long edge), this will prevent warping when the concrete is poured.

Lastly, cut the mesh to size. the correct size is when the mesh is in the center between the outer and inner wall of the mold. You can connect the mesh to each other using some wire or string. This will support the concrete and make the TV stand sturdier. Take out the mesh and save it for the next step.

Let the caulk dry before moving on to the next step.

Step 3: Pouring the Concrete

When you've finished the mold and are happy that it will be strong enough to hold the concrete.

get the big bucket out and mix the concrete with water. Use the mixer and a powered drill to mix the cement and use the shovel to break up any big parts. Mix until it looks like a smooth batter.

Pour an initial layer of cement into the mold. next, put back the mesh, but make sure that you do not push it all the way through the cement. also make sure you don't touch any walls. Continue pouring and mixing cement until the mould is full. Unfortunately I don't have pictures of the pouring process itself as I used fast-setting concrete :)

Next, vibrate the concrete using either a hammer, sanding machine or vibrating needle. This will take out any air bubbles making for a smoother finish and stronger TV stand. Clean the bucket before the concrete sets as you will need it later.

Now, let the concrete cure. The curing time depends differs per brand, how thick you pour as well as weather, so make sure you read the instructions on the label. In my case, I waited a couple of days before moving on to the next step.

Step 4: Removing the Mold and Finishing

CAUTION: the concrete TV stand is very heavy. It is recommended that you remove the mold with more than one person to avoid injury or breaking the mold.

When the concrete has dried, you can take out the mold. Unscrew the outer mold and back panel, and use the saw or hammer to take out the inner mold. Note that you may need to pull a little to separate the mold from the concrete.

Sand the edges of the TV stand to create for a smooth finish. Use water and a cloth to clean most of the concrete dust. Now any imperfections or hidden bubbles will be visible, which can be fixed in the next step.

Use the bucket to make smaller batches of cement fix or levelling cement. If you have used any pigment, add it here. Watch out that you match the colour of the rest of the stand. Fill the holes with cement fix and let it dry. Finally, sand away any imperfections.

To create the floating effect, cut the piece of square tubing and cut it about 2/3 of the depth of the TV stand. To create the floating effect place the tubing as shown in the picture. To avoid scratches on your floor can add felt to the bottom.

Step 5: Add-ons

I have several ideas for add-ons and how I would approach it. Please not that I have not done so yet, so please make sure you think about how you would approach it.

Doors:

Get your door hinges at Ikea or your local hardware store. Before pouring the concrete, create a carve-out out of scrap pieces of MDF the same size as the backside of the hinge. Next, screw the carve-out to the inner mold, but make sure you fix them to the correct side. The carve out should be fixed in between the outer and inner mold.

Then you can continue to pour concrete and follow the previous steps. Finally, fix the hinges to the insides of the depression that you created with the carve-outs and hand the door to the hinges.

Drawers:

Again, get your drawer rails and drawers at your local hardware store or Ikea. In your design, account for the width of the drawers and create an additional vertical wall if necessary. Follow and finish the steps before. Finally, attach the drawers to the inside of the TV stand using a concrete drill, some plugs and screws.

Qi Charger:

Follow the steps mentioned earlier. Use a carve-out out of a piece of scrap MDF to create a depression in the concrete on the outer panel. After finishing up the previous steps, drill a hole through the concrete to hide wiring and put in a Qi charger to the top of the TV stand. Possibly, add a layer of coloured concrete to indicate where the charger is located.