The raw TV frame
It looks like the TV manufacturer is NOT going to give me a TV for this project. Bummer, it was close but no cigar. I decide to go with their best 62” even though I will have to pay for it. I'm still smarting from the hot ticket 386 computer setup I bought in 1986 that cost $8000.00 (that’s like $16K today) and was shot dead and absolutely worthless with the Y2K thing. As much as I hate to buy electronics that cost a fortune and are out of date before you get them out of the box, I write the check. It will serve us for many years to come and it should get the kids off my back about our old weak setup. It’s also an incredible value these days considering that a 62” screen with lower resolution cost $25k just a couple of years ago. I go to Shelly’s where Alon cuts me a great deal and then drive over to the warehouse to pick it up. The box is HUGE! Maybe I overdid this!!?? Nahhh…anyway it’s to late now, the unit is committed. Bryce gets home from school and sees the giant TV box in the truck. He is a very happy camper. I tell him to break down the old system and clear the space so we can set the new TV up to get the measurements I need to build the frame. We have it out of the box and temporarily in place and it is… HUGE. But it looks good and from where the couch sits it turns out to be the perfect size for the space. I get the dimensions I need and off to the shop I go to build the frame.
In the beginning of this affair I purchased what I thought was enough solid wood to do the entire job. That is important when you use wood that varies in color as much as mahogany does. Unfortunately on close inspection one of the boards I was counting has grain that is not up to grade. I need to get a replacement. That’s not too big a problem but it is a big hassle nonetheless. I figure I’ll go to my local supplier Conejo Hardwoods to save me the long drive to Far West Plywood. They always have nice stuff and do again on this trip. I grab what looks like the right color and grain then head back.
I am mitering the frame together to have it look like a picture frame. I have the new Delta 12” 36-412 dual compound miter saw that will cut the 5” parts pretty close. I will hand fit each joint afterwards by trimming them in on my 20” disk sander. I get that all done then look closely at the piece that I just bought… and the color is way off! Mahogany varies as mentioned but the main stock is red and this piece is gold. I put water on it to see if the thing will fly and it’s not doing it. Not good. I go back to the original stock I first rejected and fit that in hoping that it will look better. I hassle with the fit then get it done. The color is good but the grain is way inconsistent with the rest of the job. Of course that is why I first rejected it but I was learning to love it especially after all that work and expense. My wife happens in and takes a looks at it. She tells me what I already know but was justifying in my mind. “How come that piece doesn’t match?” Much swearing, cursing (not at my wife, at the wood) and a dreaded trip to the original supplier Far West and back ensue. An hour and change later I was cutting the third piece in for that part! It wasn’t as perfect a color match as I would like for all that trouble but it’ll do just fine dagnabit! The good news about mahogany is in six months all this wood will look close to the same color and a lot darker to boot. I glue it up and call it a day. Time to get out of the shop and go for a ride.
The next day I fit the inner trim. It’s a little tricky and I have to model the frame to the TV. It’s a short walk to the house but I have done it a million times. One of the worst things about having a shop seventy-five feet from your house is that it’s not that hard to double check things or take parts back and forth to make them fit perfect. And so I do. I think I have walked a couple of thousand miles seventy-five feet at a time working on our house.
I find a nice piece of figured maple in my rack that will do the trick for the inner trim. I mill it all out and then do the final fit before I break it down for finish. Everything is complete and we can now install the unit.
Next up is Dday, the big install, where the rubber hits the road. We will know for sure after that if I’m a hero or an idiot.
