This project was built and designed by Steve from JKM Woodworking. It’s a rustic-style console table that doubles as a TV cabinet, complete with sliding barn doors and shaker-style accents for a clean, functional design.
Designed with versatility in mind, this piece can serve as a media center, entryway table, or stylish storage unit. With careful planning, quality materials, and a few clever build techniques, Steve walks through every stage of the process to create a durable and attractive piece of furniture.
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Project Goals and Materials
The cabinet is built primarily from knotty alder plywood and solid alder boards. The plywood serves as the body of the cabinet, while the face frame and trim are made from knotty alder to add character and warmth.
Sliding barn doors are a key part of the design, giving the piece a distinct look while providing easy access to the shelves. The project also includes adjustable interior shelving and a clean, finished back.
Planning and Layout
Steve starts by designing the piece in SketchUp, which helps generate accurate cut lists and material estimates. The design is planned around a single sheet of plywood to reduce waste and cost.
Precise planning also makes it easier to batch cut components, keep the build organized, and avoid surprises during assembly.
Breaking Down the Sheet Goods
The plywood is cut down using a circular saw and a budget-friendly straight edge. Steve makes shallow initial cuts to reduce tear-out and completes the breakdown into side panels, shelves, and dividers.
With the rough sizes cut, the project moves to the table saw for fine adjustments and dado setup. Dado slots are used to join interior panels securely while keeping the structure square.
Shelf Pin Holes and Assembly
To make the cabinet more versatile, Steve drills shelf pin holes along both sides of the interior. He uses a simple jig for accurate spacing, allowing the shelves to be adjusted up or down depending on use.
Assembly begins by attaching the vertical panels, followed by horizontal supports at the top. Pocket hole screws are used for parts that will be hidden, offering fast, secure joints without visible fasteners.
Adding a Back Panel Recess
A rabbet is cut around the rear edge of the cabinet to hold a quarter-inch plywood back. This step strengthens the frame and provides a clean enclosure for the finished piece.
Once assembled, the carcass is dry-fitted to ensure everything lines up, and final sanding is done before trim work begins.
Edge Banding with Scrap
Instead of using iron-on edge banding, Steve creates his own from scrap alder. These strips are glued in place and trimmed flush using a router with a flush-cut bit.
This method gives the cabinet a more refined look and helps the shelves match the rest of the face frame, creating a unified finish throughout.
Building the Face Frame
The face frame is made from solid knotty alder and joined using dowels for strength. Steve applies glue to the end grain before assembly to improve bond strength, especially on pieces with exposed knots or uneven grain.
Alignment is key here, and the frame is clamped tightly until the glue dries. Once attached to the cabinet, the edges are trimmed and sanded for a seamless fit.
Bottom Trim and Shaker Doors
Steve then cuts the bottom trim using the jointer for clean, straight edges. Dark brown CA glue is used to fill small cracks or voids in the wood, adding strength while maintaining the rustic look.
The doors are built in a shaker style, using a tongue-and-groove router bit set to create the rails and stiles. Steve assembles the frames first, then marks for cross pieces before adding the center panels.
Applying the Finish
Finishing starts with a coat of shellac to prevent blotching. This is followed by a dark gel stain, which enhances the knotty alder’s natural patterns and warmth.
For added depth, Steve mixes dye into a lacquer topcoat to create a subtle, tinted finish. This extra step gives the piece a rich, layered look without hiding the wood grain.
Final Assembly and Hardware
The top is attached using tabletop fasteners, allowing the wood to expand and contract naturally over time. A 1/4″ plywood panel is nailed onto the back, providing a clean finish.
Barn door hardware is installed last. Although the kit is pre-made, Steve makes adjustments to improve the door alignment and ensure a smooth sliding action.
A Functional and Beautiful Centerpiece
This barn door console table is both a stylish and practical addition to any home. From detailed planning to final assembly, Steve showcases the kind of thoughtful woodworking that results in heirloom-quality furniture.
Whether used in a living room, hallway, or entryway, this piece offers flexible storage with a unique look. It’s a project that highlights the beauty of knotty alder and the craftsmanship behind functional furniture.
Watch the full video and subscribe to Steve’s channel: