Flat screen TV Installation

A few people have asked me for details on how we replaced our old heavy picture-tube type TV with a newer flat screen. It's easier to do it here in the blog than by a series of e-mails so here is how we did it:

Obviously, every situation is different, but you might get some useful ideas.

Click the photos for a larger view.

The first thing we did was have the TV surround and the old TV removed by the techs when we had the rig in the shop for something else!



Next we measured very carefully the inner dimensions of the steel cage that had held the old TV. We then visited every TV retail store in a 40 kilometer radius with our measurements and tape measure in hand to find the one that fit best. This actually took a few trips to fine tune, as it soon became obvious that the wooden cabinetry might have to be modified. This is something that I could do, but would prefer not.



Eventually we found a 28" Toshiba that was designed with a slight lip around the screen, the back slightly recessed all round--about 1/4 to 3/8 of an inch. It just fit in the space, the lip keeping it from falling through. Now all we had to do was figure out how to secure it so that it would stand up to the vibration. We purchased a couple of wall mount systems but quickly realised that for several reasons would not be ideal. The main problem was that they would be difficult to attach and secure in our particular setup.





We were also changing some of the other equipment--adding a DVD/VHS recorder and a StarChoice digital recording satellite so there were a lot of cables to be changed or added. Before we procedeed we set up all the equipment on a table in the house, connected everything, measured to ensure that the cables would be log enough.

We then labled each end of every cable...boy, were we glad we did!






A little investigation revealed that the plastic stand attached to the bottom of the TV came off with a couple of screws and inside this plastic stand was a metal bracket that actually carried the weight and which could be very easily removed--in fact it almost fell out.

This metal bracket was used unmodified other than screwing a block of wood to it. This would take the weight and would be secured to the steel base by a couple of wood screws from below. To keep the TV from falling out frontwards we had to devise a bracket that would allow us to secure the back of the TV using the same holes provided for the commercial brackets on the back of the TV.



Scrounging in the workshop revealed a few scraps of mahogany that had once been part of a set of bi-fold closed doors! A little time with tape measures, saws, clamps and glue produced a wooden bracket that could be bolted to the steel frame to provide an attachment point for the back of the TV. How to make that attachment caused a bit of thought and again rummaging about in the shop resulted in a couple of brackets made from a pair of small gate hinges.



The critical part of this was getting the height and horizontal placement of the back support placed exactly right. The wooden cross bracket was held in place temporarily using a couple of C clamps, the hinges attached to the TV and everything adjusted up, down, front, back until the placement was perfect. This was done by Gillian preventing the TV from falling forward while Art reached around through the small access holes on the side making adjustments and pencil marks. This took a little longer to do that write about!




With the C clamps still in place the bracket and steel cage was drilled and steel bolt and fender washers held it firmly in place. Next the TV was removed and the strap hinges removed from the TV and screwed to the wooden bracket at the pencil marks. To check that all was OK, the TV was put back in, and Art reached through the access holes gain to make sure the holes in the hinges lined up with the screw holes in the back of the TV. Good thing we checked--one hinge was a bit low! This only needed a moment in the shop with vise and hammer! Next try was perfect.



Now to attach the cables--wish we had a photo of this procedure but we didn't have a spare hand to operate the camera!

Gillian held the TV tilted forward and a bit sideways while Art reached around and attached the cables. We had previously arranged all the wires in order from left to right which made things a bit easier and a lot faster.


Now the TV was lifted and pushed into place, the back screws put in by once again reaching around the back and when tightened, screws up through the bottom of the steel cage into the wooden block on the bottom bracket ensured nothing was going to move. We also put a bead of silicone seal between the wood and the steel, just thinking it may dampen out a bit of vibration.
We next re-installed the other equipment and tested everything. It all worked!!!


Now to see if the plastic surround and the cherry cabinet would fit with out too much trimming-- It went in perfectly!!! The inside of the front face just touches the front of the TV Screen! We probably could have gotten away without any of the brackets, though I wouldn't want to risk it. After more than 14,000 kilometers, some on very rough roads, the TV is still secure and working well.

(Edit January 2011--another 30,000 kilometers including Akaska'd Top of the World gravel highway all is still secure.



















As a final touch to fill in the gaps left above and below the TV screen I made up fillers out of scrap wood and covered them with black vinyl. The bottom 2 pieces are just a press fit--very snug and don't move. The upper one is secured with velcro for now but I will replace that with a couple of brass screws when we get home.

There are small spaces left top and bottom for air circulation.






Afterword

In May 2009 we attended the Spring Rally of the Vancouver Islanders chapter of FMCA at Sandown Harness Racing track in Sidney BC, just north of Victoria.

Here we discovered that fellow members in an identical rig to ours had found a different way.

They used the identical TV but mounted it by a swing arm bolted to the steel frame, secured by a velcro strap on the top. This has both advantages and disadvantages. On the plus side, making or changing connections is very easy--the weight of the TV is supported by the arm and there is room behind for storage. Our friends added a shelf for videos, dvds ect. and also mounted the TV a bit higher than ours. This made space below for their satellite reciever. This idea we like very much.

The major drawback of this system is that the TV is outside of the stock wooden cabinet, which need to be modified. Fortunately Wayne is quite a good craftsman and was able to match the original cherry finish for a very professional appearance.

Now Art is seriously contemplating the same move. Maybe that will motivate him to clean up his shop! (January 2011--still not done!)