“The drawer! The drawer!”
An excitable crowd urges Hayley McAuley to look again. The 38-year-old from Wigan has just finished assembling a white bedside table and is already packing away her tools, convinced she has retained her title at the Flatpack World Championships on the opening day of Grand Designs Live in London.
But she hasn’t noticed the slightly wonky drawer.
Around her, three fellow finalists – two of them also professional flatpack builders – are still working, the tension mounting. Then, within seconds, McAuley spots the mistake. This is the moment she has trained for.
She fixes it quickly. With slightly trembling hands, she drives in the final screw.
Cheers erupt as her time flashes on screen: eight minutes and 20 seconds – smashing her 2025 personal best of nine minutes and 33 seconds. McAuley breaks into a relieved smile and raises two thumbs in the air.
It is a victory years in the making.
“I knew I was good from when I was about nine,” says McAuley, now a warehouse team leader. “My dad would build something and I’d notice things he’d done wrong – I’d step in to fix it. Most people are overwhelmed by all the screws and fittings, but it doesn’t bother me.”
What began as a natural aptitude turned into a flatpack support business in 2024, after she posted a photo on Facebook of furniture she had built for her stepdaughter and was flooded with requests. When a friend mentioned a radio advert for a competition, McAuley saw an opportunity to take things further.
Now a two-time champion, she is already planning her defence.
After posing with her golden Allen key medal, the emotion catches up with her. She speaks about her aunt Vanessa, who had hoped to be in the audience but is currently undergoing cancer treatment. “I can’t wait to tell her,” she says, wiping away a tear.
The competition may be light-hearted, but the recognition is not. Flatpack assembly is rarely celebrated, yet McAuley’s success gives it a moment in the spotlight – and, for her, it carries real meaning.
“It’s actually my best achievement,” she says. “I really wanted it – and the fact I did it means everything.”
Most people won’t be chasing records with an Allen key. But McAuley’s approach offers lessons anyone can use…
Start the right way
“People often don’t read the instructions properly – and that’s where it goes wrong. Read them from start to finish first, not just step one. It helps you to understand the whole process.
“Then empty everything out and check every piece against the manual – right down to the screws. You don’t want to get halfway through and realise something’s missing.”
Don’t overtighten
“Don’t tighten everything fully straight away. If you make a mistake, it’s much harder to fix – and you can even break screws trying to undo them.
“My rule is to keep things loose until the end, then secure everything once you know it’s correct.”
Use the right tools
“I always recommend a Pozidriv screwdriver – it grips better and stops slipping. And use a rubber mallet instead of a hammer. If you hit plastic fittings with a hammer, you can easily break them.”
Choose wisely
“I work with lots of brands, and I’m always happiest when customers pick Ikea. The quality is consistent and the pieces are sturdy.
“Also think about materials. Metal furniture can be tricky – lots of tiny fasteners, sharp edges and alignment issues. Wood or plastic is much easier if you’re building it yourself.”
Don’t get stressed
“People get frustrated because they expect it to be easy – but it isn’t for everyone. If you’re getting annoyed, step away and come back later. You’re not being timed.
“And one last small tip: trim your nails. It makes handling tiny screws much easier – it sounds silly, but it saves a lot of time.”