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Need a custom fit piece of walnut

February 25, 2011, 09:40:59 pm

I am in the process of replacing our recently departed Sony TV with a flat panel TV that I will hang on the front of the existing cabinet.

Because the existing cabinet is several inches taller than the new TV I'd like to put a piece of walnut between the top of the TV and the ceiling.

For use as a template, I can easily cut off the top section of the old walnut "frame" that held the previous flat panel TV within the cabinet and mail it to whoever volunteers to make this piece of wood for me.  My existing piece will provide the curvature of he ceiling.  The new piece will be approximately 25.7 inches wide and about 3 and 5/8ths wide x whatever thickness you have in stock, but 5/8 to 3/4 would look best.  Note:  the existing top portion of the frame is not wide enough to use as is.

I expect to pay time and materials and shipping.

Any volunteers?

 

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Re: Need a custom fit piece of walnut

Reply #1 – February 26, 2011, 08:29:19 am

Hi George
We recently replaced the old TV in the livingroom with a new flat panel LCD also.  We found that it would be very difficult to replace the walnut wood trim to match the other wood cabinets so we used plywood and covered it with the same carpet from the ceiling.  We called FT and bought the carpet directly from them at a very reasonable price (shock, shock!) We also scavenged a piece of the walnut plywood to fill in the gap on the left side of the cabinet that was exposed due to the removal of the original TV enclosure.  I've attached some photos for you to see what I'm talking about. 

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Re: Need a custom fit piece of walnut

Reply #2 – February 26, 2011, 03:13:21 pm

Bob and Faith,

A possible solution.  Two questions:

1.  How difficult is it to fold that carpet around the board and staple it in place?

2.  I assume you covered a radius.  Was that difficult?

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Re: Need a custom fit piece of walnut

Reply #3 – February 26, 2011, 03:44:44 pm

First I made a cardboard template to fit around the TV using the old TV enclosure to match the curve of the ceiling.  Then I cut it out of lightweight plywood and assembled the pieces.  I cut the carpet from one large piece and then I sprayed the back of the carpet and the wood with 3M contact adhesive.  The frame I made only has one square corner and I just wrapped the carpet around the corner.  The carpet is lightweight and easy to work with.  To hold it in place I put a small bracket at the top left corner and on the right hand side it's screwed directly to the cabinet.  I can remove it to get to the back of the TV if needed.  I did wrap the carpet around the board and stapled it in place at the bottom portion where it touches the TV.  I thought this would help with a tighter fit next to the TV as well as act as a cushion against the top of the TV set.  The bottom is left open for access to wires and such.    Bob

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Re: Need a custom fit piece of walnut: Solution Found

Reply #4 – March 08, 2011, 10:35:41 pm

Necessity is the mother of invention.

Not being able to find a piece of walnut I substituted a piece of half inch knot-free pine I found at Lowe's for about $5.00.  I cut it to fit, sanded and then sprayed 10 coats of high gloss black lacquer on it to match the black mask around the outer edge of the TV.  I attached it with two small wood screws also painted black.  We are pleased with the look.

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Re: Need a custom fit piece of walnut

Reply #5 – March 08, 2011, 10:57:15 pm

Hi George,
  The black piece looks fine!

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