I'm currently working on a big commission for a gaming store, building a gaming panel that will be mounted on a wall by the entrance. This is my first time handling a larger woodworking project on my own and I'm feeling a bit overwhelmed. The panel measures 350cm x 250cm and sticks out about 12cm from the wall. I'm constructing a frame using 2x4s to support the high-quality plywood panel, where I'll also cut out sections for screens and other components.
Despite my best efforts, I'm struggling to get the frame perfectly level, with measurements showing a deviation of about 1 to 3mm (which translates to 1/32" to 1/8"). I think the issue might be the inherent warping of the 2x4s I'm using. A fellow woodworker told me that chasing perfection with 2x4s is unrealistic unless I plan to plane them for uniformity. I'm wondering if this deviation will cause problems since the frame will be hidden once covered with plywood?
2 Answers
If you're really worried about the frame, you might consider switching to plywood or MDF for the structure instead of 2x4s. They’re easier to work with and can provide a more uniform surface. Just keep in mind how you'll attach the heavy plywood sheets to that frame!
Your colleague is spot on! It's really tough to achieve perfection with construction lumber. Those small variations usually won’t be visible once everything is in place, and more importantly, they shouldn't affect the functionality at all. So don't stress too much about it!
Thanks for the reassurance!
How would I attach the sheets of plywood to a plywood frame? The front sheets are pretty heavy, around 123kg total. I originally thought 2x4s would provide more strength, especially since it’s going on drywall over steel framing.