Project Overview

If you like the industrial look, then you’ll love the mix of wood and black metal in this industrial wooden TV unit. It’s an easy unit to make, can be conveniently moved around on wheels and gives you great looking storage space for your lounge room.

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How to cut a bolt to size using a drill

Cutting through a bolt can be hard work. To make it easier, let your drill do the work for you. Screw two nuts onto the bolt at the length you want the bolt to be. Then tighten them up against each other. Put the bolt into your drill’s chuck and tighten it. Turn the drill on and firmly hold the hacksaw against the spinning bolt, near the nut. The blade will cut the bolt, and the nuts will steady the spinning bolt and clean off the burrs when you unscrew them. And there you have it, a simple tip for cutting a bolt to size.

Step by Step Instructions

1 Cut the timber to size
2 Plane the timber
3 Join the timber together
4 Chisel and sand the timber
5 Measure and mark for the flanges
6 Measure and mark for the castors
7 Finish off the shelves
8 Spray paint the fittings
9 Countersink for the bolts
10 Attach the flanges to the first shelf
11 Attach the second shelf
12 Attach the top shelf
13 Attach the castors
14 Sit back and relax
  • Step 1. Cut the timber to size

    To make this project easier, you can have your timber pre-cut to size at your local Bunnings. We had the hardwood cut into 6 lengths of 240mm x 45mm x 1500mm.

  • Step 2. Plane the timber

    For the TV unit width, you’ll need to join two pieces of 240mm x 45mm x 1500mm timber together. So the joins fit together neatly and squarely, give the long edges a plane. When using the plane don’t take too much off at once. Repeat the process for the other pieces of timber.

  • Step 3. Join the timber together

    To join the timber, apply glue to the edges. Then tightly clamp them together. Make sure you follow the manufacturer’s instructions on the glue’s label for the drying period. Repeat the process to make the two other shelves.

  • Step 4. Chisel and sand the timber

    Use a chisel to remove any excess dried glue where you’ve joined the shelves. Then give the shelves a sand to smooth them with a belt sander. Start with 80 grit sandpaper and then use 240 grit for a fine finish.

  • Step 5. Measure and mark for the flanges

    The supports for the shelves are made from galvanised pipe and flanges.  Starting with the bottom shelf, measure and mark for the flanges. We used six flanges on each shelf. Position them 15mm from both edges and in the centre.  Pre-drill using a 7mm drill bit. You’ll then need to do this for each shelf.

  • Step 6. Measure and mark for the castors

    On the bottom shelf, mark and pre-drill for the six castors, which will be fixed to the underside of the bottom shelf. Make sure you offset the castors and leave room to screw in the flanges. Our castors were 10mm from the external corners and the centre. Pre-drill these from the top down. 

  • Step 7. Finish off the shelves

    Once you’ve finished drilling, sand back any rough edges with the orbital sander. Then finish the shelves with a natural wax, which seals the timber and brings out its natural grain. Let the timber cure.

  • Step 8. Spray paint the fittings

    To create the industrial look, you can spray paint all of the fittings black. Leave them to dry, applying as many coats as necessary. When spray painting always work in a well ventilated area and use the appropriate safety gear. 

  • Step 9. Countersink for the bolts

    You need to countersink the holes for the flanges on the underside of the bottom shelf. This will ensure the castor plates are flush with the wood.

  • Step 10. Attach the flanges to the first shelf

    Attach the flanges to the bottom shelf with a socket wrench. Screw the upright 250mm galvanised pipe into the flanges. Then attach another flange to the top of the threaded rod. You’ll need to do this six times for this shelf.

  • Step 11. Attach the second shelf

    Place the second shelf on top of the flanges and screw flanges to the top of the shelf using the 75mm bolts and nuts. Then secure the shelf by screwing your flanges in from the bottom up. Once the top flanges are in, screw in a 125mm galvanised pipe, and put more flanges on top. A good tip is to cut the bolts off with an angle grinder for a nicer finish.

  • Step 12. Attach the top shelf

    Place top shelf on top and screw the nuts straight down and into the flange underneath with 75mm bolts and nuts. Fix in and screw in the 50mm bolts from underneath. Hammer in the bolt so that it sits flush with the unit top or you could countersink these bolts for a nice finish.

  • Step 13. Attach the castors

    Fix four castors onto the underside of the base. Put the 50mm bolt through from the top side, and screw in the nut underneath to secure.

  • Step 14. Sit back and relax

    Now it’s time to move the TV unit into your lounge room. Turn the TV on and relax in front of your favourite show.

Tools and Materials


  • 10mm socket wrench
  • Angle grinder
  • Belt sander and 80 grit sanding belt
  • Circular saw
  • Combination square
  • Cordless drill
  • Drop sheet
  • Dust mask
  • Earmuffs
  • Impact driver
  • 7mm clearance bit and countersink bit
  • 10mm socket head
  • Measuring tape
  • Orbital sander and 120 grit sandpaper
  • Pencil
  • Plane
  • Safety glasses
  • Sash clamps x 4
  • Straight edge clamp
  • Work gloves


  • 240mm x 45mm x 4.8m hardwood x 2
  • 250mm x 20mm galvanised pipe x 6
  • 120mm x 20mm galvanised pipe x 6
  • 75mm x 5mm cup head bolts
  • 50mm x 5mm cup head bolts
  • 20mm flanges x 24
  • Cast alloy caster wheels x 6
  • Polyurethane glue
  • Spray paint
  • Wood filler
  • Wood wax

Health & Safety

Please make sure you use all equipment appropriately and safely when following the advice in these D.I.Y. videos. You need to be familiar with how to use equipment safely and follow the instructions that came with the equipment. If you are unsure, you may feel it is safest to consult an expert, such as the manufacturer or an expert Bunnings Team Member.

Grave health hazards are linked to asbestos, which may be in homes built up to 1990. Health hazards may result from exposure to lead-based paints in older materials and copper chromium arsenic (CCA) treated timber. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page. You can also use a simple test kit from Bunnings to indicate the presence of lead-based paint.
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