STEP 1 – MEASURE & CUT
Measure – TV overall size, Bezels -top, bottom, and sides. Also the thickness of your TV.
Measure and cut your frame sticks four inches larger than the overall size. For example, if the overall dimensions are 43″ x 27″ cut two frame sticks at 47″ and two frame sticks at 31″.
Cut the inside of your frame on the table saw to fit over the bezel of your TV.
Some bezels may be larger than others. Measure each top, bottom and side bezels.
Calculate the outside measurements of the frame sticks. You can do this by adding the frame width (times 2!) to the view able area of the TV. Cut your 45 degree angles. Test your cuts on the view able area of the television like in the image above.
Once you’ve double checked your overall size, you are ready for gluing. Grab the front four sticks to begin the front of the build.
STEP 2 -JOINING YOUR FRAME
Start gluing one long stick and one short stick together.
For a tighter more seamless bond prop up the end of the long stick to bring the corners of the frame together. You can do so with a rubber shim.
Once both of your corners are together with glue, use the long clamps. Bring together all four frame sticks.
STEP 3 – THE BACKBUILD
Here is an example of the back build we are going to create. We make this by cutting four more sticks and gluing them to the back of the frame. We completely encase the television in frame material to hide it.
First test the front of your frame on top of your television. Adjust the frame with a hand held router if it does not fit.
Lay the frame face down and measure the size mirror you will need. Cut and place the mirror within the frame.
To measure what size back build you will need place the TV and mirror into the frame.
Now we need to figure out the thickness of the back build. You will want the back of the television flush with the back of the frame. Measure that distance and make the cut.
Cut your four remaining sticks the the back build thickness.
Once you have all four sticks cut, take them to the chop saw to cut the forty five degree angles. The size of the sticks should be 1/16″ on each stick than the front four.
Add on any last minute touch ups that will blend the two sticks together. Then glue the backbuild on. For example we are using a grey furniture marker in the image above.
Glue on your back build pieces.
STEP 4 – THE IR SYSTEM & Z-BAR HANGERS
Find the IR sensor on your television. Some will be internal and some external. For this guide we are going to show you how account for a sensor located on the outside of the television.
Measure the amount of space needed to create an empty pocket for your sensor to fit. We are using a router.
Above is the finished router hole.
Place the TV back inside to test out the space you created for the sensor.
Now we are ready for the aluminum z-bars. Place them on all 3-4 sides of the television.
Image with all sides using the z bars. This television fit flush within the thick frame. It did not need the extra four sticks for the back build.
Corner brackets to attach the front and back of the frame are optional.
IR emitter, eye, connecting block and 12volt adapter.
Once you attach the IR, let the small IR eye hang down so it can communicate with the remote.
Plug in your 12volt adapter powering the system and test the television.
Test your television and turn off “Eco Mode”. That will prevent the television from reading the light in the room. Turn up the televisions brightness and back light in more reflective environments.