One of the latest projects I’ve been tinkering with is building a custom outdoor television enclosure for our covered deck. This has been a bit of a trial-and-error journey, but I’m enjoying the challenge of blending function, durability, and a little bit of rustic design.
The TV: A Big Experiment
The centerpiece of this build is a 6-year-old 84″ Samsung television that I picked up used. It’s definitely not designed for outdoor use, so this whole project is a balancing act between creating a functional outdoor entertainment setup and protecting the TV as best as possible.
The TV sits beneath an overhang, which will shield it from direct rain or snow, but there are other factors to consider:
- UV Exposure – Sunlight may cause fading or heat buildup over time.
- Humidity & Condensation – The biggest concern. Moisture inside the TV can easily lead to permanent damage.
For now, my plan is to leave the TV installed during the drier months (late spring through early fall) and possibly relocate it into our basement when humidity spikes. I’ll also experiment with desiccant bags inside the enclosure to help mitigate condensation.
The Enclosure Build
The frame of the enclosure is constructed primarily from 2x4s and pine shelfboard, giving it plenty of structure to hold the TV securely. To finish the look, I decided to get creative with some upcycled pallet slats.
Each pallet board was milled with a shiplap groove, giving the front a rustic but clean look. For trim, I used cedar fencing pickets, which tie in nicely with the natural wood siding of the cabin. I considered a cedar tongue and groove to match the exterior wall, but since this protrudes out as much as it doesn’t, I wasn’t exactly looking to blend it in. The cost of cedar was once again a huge cost deterrent and made the upcycled pallet slaps that much more appealing for this build as well.
Initial frame build, showing the TV mounted inside.
Access & Usability
One of the challenges with a big, heavy front panel is making it easy to open and close. To solve this, I’ll be installing gas struts—similar to what you’d find on the liftgate of an SUV. These will help support the weight of the door, making it safer and smoother to access the television.
Next Steps
This project is still in progress, but upcoming steps include:
- Installing and testing the gas struts. I’ve had to return a couple pair so far.
- Weather-sealing the edges for added protection.
- Experimenting with moisture control solutions.
- Adding a latch system to securely hold the front panel open.
It’s a mix of function and experiment. At the very least, this enclosure should give us a fun summer setup for outdoor movie nights, even if the TV’s long-term survival is still a bit of an unknown.
Lessons Learned So Far
- Coming soon.