Flat-pack furniture assembly has a reputation for frustration, but it doesn't have to be that way. With the right approach, tools, and techniques, assembling a TV stand can be a straightforward—even satisfying—experience. Drawing on years of furniture retail experience, here's how to tackle your next assembly project like a professional.
Before You Begin: Preparation Is Everything
Professional assemblers know that preparation accounts for half the success. Rushing into assembly without proper setup leads to mistakes, missing pieces discovered mid-way, and unnecessary frustration.
Choose Your Work Space
Select a large, clear floor space with good lighting. The living room might seem convenient, but if it's carpeted, consider assembling in a garage or kitchen where dropped screws are easier to find. Lay down a clean drop sheet or old blanket to protect both the floor and the furniture panels from scratches.
Ensure you have enough room to lay out all panels simultaneously. Cramped spaces lead to pieces leaning against walls, falling, and getting damaged. A minimum of 3x3 metres is ideal for most entertainment units.
Unpack and Inventory
Open every box and carefully inventory the contents against the parts list. Check each panel for damage—scratches, chips, and dents are easiest to address before assembly begins. Count every screw, dowel, and cam lock. It's frustrating to discover a missing component after two hours of work.
Professional Tip
Separate hardware into small containers or pile them on paper plates labelled with their type (e.g., "cam locks," "shelf pins," "long screws"). This organisation saves immense time during assembly.
Essential Tools for Success
Most flat-pack furniture includes a basic allen key, but relying solely on the included tool makes assembly slow and tiring. Having proper tools transforms the experience.
Recommended Tool Kit
- • Power drill/driver: Essential for large projects; use low speed settings
- • Allen key set: Various sizes; L-shaped and T-handle versions
- • Phillips and flathead screwdrivers: Multiple sizes
- • Rubber mallet: For tapping pieces together without damage
- • Level: Ensures straight, balanced assembly
- • Pencil: For marking positions
- • Measuring tape: For verification
Reading the Instructions
Yes, actually read them. The most common assembly mistakes stem from people who think they can figure it out as they go. Modern flat-pack instructions are generally well-designed, with clear diagrams showing exactly what connects where.
Before touching any parts, read through the entire instruction booklet once. This gives you an overview of the assembly sequence and helps identify any steps that might be confusing. Note any warnings about which pieces should not be fully tightened until later stages.
If instructions seem unclear, search YouTube for assembly videos specific to your furniture brand or model. Many manufacturers provide official assembly videos, and countless DIYers have documented their experiences with popular products.
Assembly Best Practices
Work in Sequence
Follow the steps in order. Instructions are sequenced deliberately—certain pieces must be attached before others can fit. Skipping ahead often results in having to disassemble and restart. If a step seems unnecessary, trust the engineers who designed the assembly sequence.
Hand-Tighten First
When using cam locks and bolts, insert them by hand first to ensure proper threading. Cross-threaded screws are difficult to remove and can strip the pre-drilled holes. Once you're confident the screw is threading correctly, use your tool to tighten.
Don't fully tighten anything until the step explicitly says to. Many assemblies require pieces to remain loose for adjustability until the structure is complete. Premature tightening can create alignment issues that become impossible to correct.
Common Mistake to Avoid
Over-tightening is worse than under-tightening. Engineered wood (MDF and particle board) strips easily when screws are forced too tight. Stop tightening when the screw feels snug—it doesn't need to be torqued.
Use a Rubber Mallet
When pieces need to be tapped together, never use a hammer directly on the furniture surface. A rubber mallet distributes force without denting or chipping. If you don't have a mallet, place a folded towel over the area and tap gently with a hammer.
Two-Person Operations
Many TV stand assemblies include steps best done with a helper—holding a back panel in position while attaching it, for example, or lifting a completed unit upright. If instructions suggest two people, heed that advice. Attempting awkward manoeuvres alone risks both personal injury and furniture damage.
Understanding Common Hardware
Flat-pack furniture uses specific hardware types repeatedly. Understanding how each works prevents confusion.
Cam Locks
Cam locks are the circular fittings that lock into cam bolts. Insert the cam lock into its hole with the arrow pointing toward the entrance hole for the cam bolt. Insert the bolt through the adjacent panel into the cam lock, then rotate the cam lock clockwise to tighten. The arrow should end up pointing away from the entrance hole when fully locked.
Wooden Dowels
Dowels align panels and add structural strength. They should push in snugly by hand or with light mallet tapping. If a dowel won't fit, check that you're inserting it into the correct hole—similar-looking holes may have different diameters.
Shelf Pins
Shelf pins fit into pre-drilled holes to support adjustable shelves. Ensure all four pins for each shelf are at the same height before placing the shelf. Metal pins with rubber grips hold shelves more securely than plain metal versions.
Finishing Touches
Once assembly is complete, take time for these final steps that separate amateur from professional-quality results.
- Go back and fully tighten all cam locks and screws now that the structure is complete
- Check that all doors and drawers open and close smoothly; adjust hinges if needed
- Attach any included anti-tip straps to the wall for safety
- Apply any included felt pads to the bottom to protect flooring
- Clean the surfaces with a soft, dry cloth to remove fingerprints and dust
- Keep leftover hardware in a labelled bag for future adjustments
When Things Go Wrong
Even with careful assembly, problems sometimes occur. Here's how to address common issues.
Stripped holes: If a screw hole strips and won't hold, insert several wooden toothpicks with wood glue into the hole, let it dry, then redrive the screw. For cam lock holes, the furniture may need replacement panels.
Misaligned panels: If doors or drawers don't align properly, check that the carcass is square by measuring diagonally corner to corner—both measurements should be equal. Uneven surfaces can cause racking; try repositioning the unit or shimming under legs.
Missing parts: Contact the manufacturer's customer service. Most reputable brands will ship replacement parts free of charge. Keep your purchase receipt and order confirmation handy.
With patience and proper technique, flat-pack assembly becomes a manageable task rather than a dreaded chore. The satisfaction of building furniture with your own hands—and the money saved over professional assembly—makes the effort worthwhile.
David Park
Content Writer
David is a former furniture retail manager with extensive experience in furniture assembly and customer service.