The box arrives, you tear it open excitedly, and then reality sets in: instruction sheets covered in cryptic diagrams, bags of mysterious hardware, and panels that all look identical. Flat-pack furniture assembly has a reputation for frustration, but with the right approach, building your new TV unit can be straightforward—even satisfying. This guide shares professional assembly tips that prevent common mistakes and lead to a sturdy, correctly-built result.
Before You Start: Preparation
Proper preparation prevents most assembly problems. Resist the urge to dive in immediately—time spent preparing saves time and frustration later.
Check the Contents
Before assembly, verify everything is present:
- Lay out all panels and identify each one using the parts list
- Count and sort all hardware—screws, cam locks, dowels, brackets
- Check for damage: dents, chips, scratches on visible surfaces
- Confirm all bags are accounted for (sometimes hardware bags are tucked into styrofoam or taped inside panels)
If anything is missing or damaged, contact the retailer before proceeding. Discovering a missing cam lock halfway through assembly is extremely frustrating.
Read the Instructions Completely
Read through the entire instruction manual before touching a single screw. This gives you:
- An overview of the process and approximate time needed
- Understanding of the sequence (some steps must happen before others)
- Awareness of where help might be needed for large panels
- Familiarity with the hardware types and how they're used
If instructions are poor quality (small images, unclear diagrams), search YouTube for assembly videos of your specific product or similar models. Visual demonstrations often clarify confusing written instructions.
Prepare Your Workspace
Create an ideal assembly environment:
- Clear space: You need room for the assembled unit plus working space. Clear more space than you think necessary
- Protect floors: Lay down a drop cloth, cardboard, or old sheets to prevent scratches on floors and damage to furniture finishes
- Good lighting: Poor lighting leads to mistakes. Work in daylight or set up bright task lighting
- Comfortable temperature: Assembly takes longer than expected. Avoid working in extreme heat or cold
Essential Tools
Most flat-pack furniture includes any specialised tools required (usually a simple Allen key), but having proper tools makes assembly easier and produces better results.
Must-Have Tools
- Phillips head screwdrivers: Multiple sizes. A screwdriver set is ideal
- Cordless drill: Not essential but dramatically speeds up screw-heavy assemblies. Use low torque settings to avoid over-tightening
- Rubber mallet: For tapping components together without damaging finishes. Never use a metal hammer directly on furniture
- Level: Essential for ensuring shelves and surfaces are even
- Tape measure: For verifying alignment and positions
Helpful Additions
- Magnetic parts tray: Keeps small hardware organised and prevents loss
- Headlamp or torch: For seeing into dark corners and recesses
- Clamps: Hold pieces in position while you secure them
- Pencil: For marking positions if needed
Key Takeaway
Using a power drill? Set it to the lowest torque setting and go slowly. Over-tightening is the most common cause of stripped holes and damaged cam locks in flat-pack furniture.
Common Hardware Types
Understanding the hardware you're working with prevents confusion during assembly.
Cam Locks (Cam Bolts)
The most common connector in flat-pack furniture. One part (the bolt) screws into one panel; the other part (the cam) fits into a hole in the adjoining panel. Rotating the cam locks onto the bolt, pulling the pieces tightly together. Tips:
- Ensure the bolt is fully inserted before positioning the cam
- Turn the cam in the direction indicated (usually an arrow on the cam)
- Don't overtighten—stop when snug
Wooden Dowels
Cylindrical wooden pins that fit into holes in adjoining panels, providing alignment and additional strength. Tips:
- Insert dowels into their holes before joining panels—don't try to insert them after
- A tiny dab of wood glue on each dowel adds permanent strength (only if you don't need to disassemble later)
Confirmat Screws
Thick screws designed specifically for engineered wood. They cut their own threads and provide strong connections. Tips:
- Pre-drilled holes should already exist—never force these into undrilled material
- Tighten until snug, then stop. Overtightening strips the hole
Allen Bolts
Hexagonal socket-head bolts tightened with Allen keys. Common in furniture with exposed bolt-head details. Tips:
- Use the correct size Allen key—forcing the wrong size damages both key and bolt
- Long-handled Allen keys provide better leverage
Step-by-Step Assembly Approach
Follow the Sequence
Instructions are designed in a specific order for reasons that may not be obvious. Jumping ahead often means backtracking or disassembling to access earlier steps. Follow the sequence exactly, especially for your first few flat-pack projects.
Hand-Tighten First
A critical technique: for each section, insert all hardware loosely before fully tightening anything. This allows for adjustment and alignment. Once everything is positioned correctly, go back and tighten in sequence.
Check Square and Level
At key stages—particularly after assembling the main frame—check that the structure is square and level:
- Square: Measure diagonals from corner to corner. Equal measurements mean the frame is square. Unequal measurements mean it's twisted—loosen fasteners, adjust, and re-tighten
- Level: Use a spirit level on horizontal surfaces. An unlevel unit looks wrong and can affect door and drawer operation
Two-Person Steps
Some steps genuinely require two people—large panels being joined, for example. Don't try to rush these alone. Having a helper hold components in position while you secure them prevents damage and produces better results.
If you strip a hole (the screw spins without gripping), don't panic. Remove the screw, insert a toothpick or wooden match with wood glue into the hole, let it dry, then re-drive the screw. This repair usually holds as strong as the original.
Door and Drawer Adjustment
Doors and drawers that don't align properly are usually adjustment issues, not assembly errors. Most modern furniture uses adjustable hinges and drawer slides.
Door Adjustment
European-style hinges (the most common type) typically have three adjustment screws:
- Depth: Moves door closer to or further from the cabinet
- Height: Raises or lowers the door
- Side-to-side: Shifts the door left or right
Adjust in small increments, checking alignment after each turn. Door adjustment is often needed after the unit is in its final position, as floor variations affect alignment.
Drawer Adjustment
Modern drawer slides also allow adjustment:
- Check that the drawer box is properly seated on the runners
- Front panel attachments often allow side-to-side and up/down adjustment
- Some slides have height adjustment levers on the runner itself
Final Steps
Finishing Touches
After the main assembly:
- Clean all surfaces with a soft dry cloth to remove dust and fingerprints
- Peel off any protective films from surfaces and glass
- Apply any edge caps or screw covers included
- Tighten all fasteners one final time
Wall Anchoring
Most TV units include wall anchoring hardware. Use it:
- Locate wall studs using a stud finder
- Attach the bracket to the back of the unit
- Secure the corresponding bracket or strap to the wall stud
- Connect the two, keeping the strap taut
This prevents tip-over accidents—particularly important if you have children or in earthquake-prone areas.
Save the Hardware
Keep any leftover hardware and the instruction manual. You might need spare parts for adjustments or if you move and need to disassemble. Store them in a labelled bag taped to the back of the unit or in a dedicated drawer.
When to Hire a Professional
Consider professional assembly if:
- The unit is very large or complex (full wall systems, for example)
- You have physical limitations that make assembly difficult
- You don't have appropriate tools or space
- The furniture is high-value and you want to ensure warranty validity
- You've attempted assembly and encountered problems you can't resolve
Professional assembly typically costs $50-150 per hour in Australia, or a flat rate for common items. Many retailers offer assembly services at the time of purchase—often worth the investment for complex pieces.
Assembly Checklist
Keep this checklist handy during your next build:
- Verify all parts and hardware are present before starting
- Read complete instructions first
- Prepare workspace with protection for floors and adequate lighting
- Gather all necessary tools
- Sort hardware into organised groups
- Follow instruction sequence exactly
- Hand-tighten all fasteners in each section before final tightening
- Check for square and level at key stages
- Get help for two-person steps—don't force them alone
- Adjust doors and drawers after unit is in final position
- Anchor to wall using included hardware
- Save leftover hardware and instructions
With patience and the right approach, flat-pack assembly transforms from a dreaded chore into a satisfying accomplishment. Your properly-built TV unit will be stable, aligned, and ready to serve for years to come.