Hayley McAuley, the current Flatpack World Champion, possesses an extraordinary talent for furniture assembly, capable of constructing a two-drawer side unit in a mere nine minutes and thirty-three seconds. The 38-year-old warehouse team leader from Wigan, who also runs her own flatpack assembly business, is now preparing to defend her prestigious title.
From Childhood Builder to World Champion
Ms McAuley attributes her remarkable skill to a lifelong passion for construction, stating that building things has always come naturally to her. Her journey began at age seven when she successfully erected a six-man tent during a family holiday in the Lake District. Just two years later, she took over from her struggling father to perfectly assemble a wardrobe, marking her first foray into flatpack furniture.
This early talent soon translated into regular requests from friends and family seeking help with various assembly projects, from beds to wardrobes. Recognising a clear market demand, Ms McAuley launched Hayley's Flatpack Assembly Service in January 2024 as a profitable side hustle.
The Path to Championship Glory
Approximately one year after establishing her business, a friend informed her about the inaugural Flatpack World Championships, held as part of Grand Designs Live. Encouraged by her friend, Ms McAuley decided to enter the competition and traveled to London to compete.
"There were quite a lot of people there so I was very nervous," she admitted. The first round required competitors to build an Ikea Billy bookcase. Ms McAuley immediately emptied her toolbox, completed the project in what she describes as a blur, and then stood smiling "like a little kid" while others continued working.
The second and final round involved assembling a two-drawer bedside table, which she completed in her record time of nine minutes and thirty-three seconds. Once again, she finished early and "just cried" from happiness while waiting for competitors to finish.
"That was one of the best days of my life," she recalled. "Because I just love doing it. Flatpack furniture may look simple, but at speed, it's a true test of skill, and a bit of chaos too."
Grand Designs television presenter Kevin McCloud presented her with a golden Allen key trophy, which she plans to bring to this year's competition in London this May.
Preparation and Training Regimen
In preparation for defending her title, Ms McAuley plans to get a hand and arm massage just before the competition begins and arrive early to assess the setup. "I'm looking forward to seeing what different kinds of people turn up," she said. "I'm not really intimidated. I'm quite confident in myself."
Her training is seamlessly integrated into her daily flatpack-building work. "I've built sheds, an octagonal greenhouse in the freezing cold, trampolines, and I've even built a motorbike," she explained. For the motorbike assembly, she charged £50 as it was her first attempt, completing it successfully and feeling "dead proud" of herself.
Her standard pricing ranges from approximately £30 for a two-door wardrobe to up to £200 for a metal shed that took three hours to complete.
Overcoming Challenges and Inspiring Others
Ms McAuley maintains an unbeaten record, with the only exceptions being when companies send incorrect parts. "Nothing's ever really defeated me," she declared, though she admitted coming close to giving up while building a trampoline in the rain, struggling with the springs.
Her passion remains undiminished, and she recently purchased wardrobes for her new home. She's also passing on her skills, teaching her partner's six-year-old daughter, who has already built the beds and side unit in her room.
"I like influencing young kids to build stuff, especially girls, because I want them to be able to do stuff for themselves," she emphasized.
Expert Assembly Tips for Everyone
For those who struggle with flatpack furniture assembly, Ms McAuley offers these essential tips:
- Organize first: Separate every screw, nut, and component, count them all, and lay them out systematically.
- Read carefully: Thoroughly review the instructions before beginning any assembly.
- Avoid permanent mistakes: Don't make irreversible assembly decisions that could require purchasing replacement parts.
Entries for the Flatpack World Championships at Grand Designs Live London 2026 are now open on their official website. If Ms McAuley successfully defends her title, she plans to create new posters proclaiming "Two-time World Champion" and admits she will "definitely will cry" again from joy.
