39 Photos - Dec 30, 2010
Photo: While building a very customized Airstream trailer for a client in an Adirondack style, I found myself in need of a solution for how to deal with the boring lifeless look of a new flat screen TV and how to mount it to the curved side wall. What I needed to come up with was a TV set that fit right into the vintage "Cabin" interior, be able to lock flat against the wall and then articulate for viewing from both the front and rear of the trailer. The following photos will show the steps I took to achieve exactly what I was looking for.Photo: After looking at about 20 new TV's in the 26" range I chose this LG model because the front was clean and void of buttons and the speakers were at the front on the bottom.Photo: I carefully removed the plastic front panel from the set.Photo: A piece MDF wood was fit in from behind where the screen goes.Photo: When you look at any old 1940's or 50's television, they all had several things in common, rounded screen corners and a gold frame around the screen. With this in mind I created curved beveled corner molds for the 4 corners and mounted them the the MDF.Photo: These corner pieces had a bevel that matched the bevel of the screen frame.Photo: I mixed Bondo and forced it into the contoured corners.Photo: After the bondo was dry I removed the corners and was left with rounded corners that just needed to be fared in with sandpaper.Photo: Once the frame was painted gold you couldn't tell the the rounded corners were not factory made.Photo: Now it was time to build the box cover so i used tempered Masonite one of my all time favorite materials.Photo: A box was built to slip over the front of the TV. It was tight on the top and sides but I made it 2" longer on the bottom so that I could make larger speaker grills.Photo: With the gold screen panel slipped in from behind, I was ready to start playing.Photo: I had an idea of where I was headed when I started the project but I didn't know where I was going to end up until it was finished.Photo: I went to an old TV and radio repair shop and found some old TV knobs that would work perfect for this project.Photo: Once everything was pre-fit and finished, I stained the Masonite with a deed Mahogany stain and then gave it about 10 coats of lacquer with a translucent Mahogany tint added.Photo: After the last coat of lacquer was dry, the whole box was sanded with 2000 grit sandpaper and then polished with automotive polish to remove and imperfections in the surface.Photo: Still playing around with the placement of the knobs and the speaker grills.Photo: Finally I figured out the perfect layout for the knobs and what to do over the speaker holes.Photo: Reproduction TV decals were purchased online and added for effect.Photo: The new LG is now an old GEPhoto: Photo: Almost finishedPhoto: Up close, the Masonite with stain and lacquer looks just like BakelitePhoto: Vintage gold and maroon grill cloth was used with strips of gold painted Masonite to create the perfect speaker grills.Photo: Holes were drilled for the 2 sensor lights on the front of the setPhoto: This knob was a great find.Photo: Although they are just dummy knobs, they look as though they would work.Photo: The real TV buttons are on the top of the set.Photo: The set is now ready for installation.Photo: Using aluminum plate and hinges I made my own articulating wall mount arm.Photo: The tapered box will take the curve out of the wall so that the TV remains level.Photo: Mounted to the wall the TV is aimed towards the front of the trailerPhoto: And aimed towards the back.Photo: Looks good from the front.Photo: Folds up flat to the wall and locks into place.Photo: Fits right into the trailer interior.Photo: Photo: After the bracket was powder coated the cables were mounted.Photo: And it's time to watch your favorite movie