How to Assemble Flat Pack Furniture Properly

Flat pack furniture has a reputation for frustration. But most problems come from rushing or skipping steps. Here's how to assemble it properly.

Before You Start

Space

Clear enough room to lay out all parts and work comfortably. More space than you think - panels need to be flipped and moved.

Time

Don't start if you're rushed. Allow double the stated time if you're new to this.

Check Contents

Open all packages and check against the parts list BEFORE you start. Finding a missing part halfway through is frustrating; finding it before you start is just a phone call to customer service.

Sort the Hardware

Group screws, dowels, and fittings by type. Put them in separate containers or bags. This saves searching mid-assembly.

Tools You'll Need

• Phillips screwdriver (usually PZ2)
• Hex key (often included, but own set is better)
• Rubber mallet (for tapping joints together)
• Tape measure
• Spirit level

A cordless drill with screwdriver bits speeds things up but requires care - don't overtighten. Our screwdriver range has what you need.

Reading Instructions

Read the entire instruction sheet before starting. Seriously. Most mistakes happen because people skip ahead without understanding the sequence.

Pay attention to:

• Which way parts face (inside/outside)
• Specific hardware for each step
• Sequence - some steps can't be undone easily

Assembly Tips

Don't Fully Tighten Early

Leave screws and cam locks slightly loose until the structure is complete. This allows adjustment. Final tighten at the end.

Dowels

Tap in gently with a mallet. If they won't go, check the hole - don't force. A drop of PVA glue on dowels adds strength (but makes it permanent).

Cam Locks

Common on flat pack. The cam (rotating disc) pulls the screw tight. Make sure the screw is fully inserted before rotating the cam. Turn cam clockwise to lock.

Working Alone

Many pieces are easier with two people. If alone, use clamps or heavy objects to hold parts in position while you fasten.

Checking Square

Before final tightening, check the unit is square. Measure diagonals - if equal, it's square. If not, loosen slightly and adjust.

Common Mistakes

Wrong Orientation

Panels installed inside-out or upside-down. Check orientation before fixing - the visible finish should face the right direction.

Missed Steps

Realising you needed to install something BEFORE closing up a section. Follow the sequence.

Over-tightening

Particle board strips easily. Tighten until snug, not beyond.

Wrong Hardware

Similar-looking screws in wrong places. Sort them first and refer to the parts diagram.

Rushing

Most errors come from trying to be quick. Slow down.

Making It Last

Flat pack furniture isn't always meant to be moved. If you do need to disassemble and reassemble:

• Mark parts so you know what goes where
• Keep all hardware together
• Some cam locks and fittings wear - replacements are available
• Reassembly in same holes can be loose - consider wood filler or toothpicks in stripped holes

Upgrading Flat Pack

Simple improvements:

• Add extra screws in critical joints
• Glue dowel joints (permanent but stronger)
• Add corner brackets inside
• Replace cheap handles with better quality

Find assembly tools in our hand tools collection.