DIY Network

Contemporary (Pt. 3 of 4): Building a Box Beam From "Kitchen Renovations" episode DKTN-104

	In this week 's episode of Kitchen Renovations, host Paul Ryan and homeowners Marshall and Jeanine convert this "old" kitchen ...
	into an eye-catching contemporary beauty!

In this third segment of Pt. 3 of the "Contemporary Kitchen," host Paul Ryan builds a box beam in order to attach the cabinets to it. This way the cabinets will align flush with the microwave. More cabinets are installed using a T-brace.

Materials:

For the Cabinet Installation

Cabinets and cabinet design
Safety gear (eye protection and gloves)
Tape for labeling doors
Drill
Impact driver
Stainless steel deck screws
Level
Rubber mallet
2x lumber (to build the box beams)
Shims
Clamps

For the Faux Painting

Paint (primer, basecoat, artist's acrylic paint)
Glazing liquid
Paintbrush and rollers
Flogging brush
Badger brush or clean soft-bristled brush
Small pieces of burlap
Graduated plastic graining comb
Artist's brush or Q-tips

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	Figure A
	Figure B
	Figure C
	Figure D

Building and Installing the Box Beam

Note: Only attach a box beam if you need to set out cabinets to be flush with appliances.

1. Cut four pieces of wood the length of the wall.

2. Use strong 3" deck screws to build the box beam. Leave one side open on each beam so you are able to attach to the studs in the wall.

3. Install one box beam for the top cabinets and one for the bottom cabinets. Set top beam high against soffit (figure A).

4. Attach the last side (figure B) of each box beam after you screw the beams to the wall, using the same 3" screws as before.

5. Once the box beams are up, it's time to attach the cabinets for this wall just like you did before for the other wall. But since the soffit may not be level, you will install the cabinets as a unit. This means you have to attach the cabinets first, then lift and attach to the wall. Once again, this is a two-person job!

6. Insert shims (Ryan used cedar shims for this particular project) between the cabinet bodies to eliminate the gap.

7. Use your quick clamps to hold the units together (figure C), and make adjustments as needed to flush the fronts and the tops and attach the units through the shims using 1-1/4" screws. Score the shims and knock the excess off with a rubber mallet.

8. Use a T-brace (figure D -- this one was an easy homemade job) to hold the cabinets as you make sure the cabinets are plumb and flush with the wall. Use shims as needed.

9. Secure the cabinets to the wall through the cleats and into the studs using 3" screws.

In the final segment, Ryan and the homeowners will install the rest of the cabinets, show you how to build the island and share some faux-painting tips.

RESOURCES :

Skil
Robert Bosch Tool Corp.
Website: www.skiltools.com

Stanley Tools Information
Stanley Tools/Works
Website: www.stanleyworks.com

Fiskars (Bucket Boss Division)
Fiskars Bucket Boss Division
Website: www.bucketboss.com

Makita Products
Makita USA Inc.
Website: www.makita.com

Paslode Nail Guns
Paslode
Website: www.paslode.com

Wolfcraft Products

Wolfcraft Inc.
Itasca, IL 60143
Phone: 630-773-4777
Fax: 630-773-4805
Website: www.wolfcraft.com

Kitchen Cabinetry (Merillat)

Brand name: Merillat Classic in Portrait
Color: Cherry Cider
Where available: Any Merillat dealer or distributor or the Merillat website (info, below)

Miscellaneous Product Information:

• WhisperGlide® drawer guide system provides quiet, smooth operation.
  
• Easy to clean, laminated interiors resist water and most household chemicals.
  
• 3/16"-thick back panels extend all the way to the floor to give extra strength and stability.

Merillat Industries
Website: www.merillat.com

Integral Blind Door (ODL)

Brand name: ODL
Model #: 686-BL
Color: White
Where available: Building materials dealers and the ODL website (info, below)

ODL Incorporated
Website: www.odl.com

970 Single Cylinder Deadbolt (Kwikset)

Brand name: Kwikset Maximum Security
Model #: 970
Color: Satin Chrome Finish
Where available: Kwikset website (info, below)

Kwikset Corporation
19701 DaVinci
Lake Forest, CA 92610
Toll-free: 800-327-LOCK (327-5625)
Website: www.kwikset.com

Delta Lever Handle (Kwikset)

Brand name: Kwikset Maximum Security
Model #: 105
Color: Satin Chrome Finish

Kwikset Corporation
19701 DaVinci
Lake Forest, CA 92610
Toll-free: 800-327-LOCK (327-5625)
Website: www.kwikset.com

Paint (Benjamin Moore)

Brand name: Benjamin Moore
Where available: Most hardware stores and the Benjamin Moore website (info, below)

Benjamin Moore
Website: www.benjaminmoore.com

Stainless Steel Bow Pulls

Brand name: Amerock
Model #: BP 19003-SS
Color: Stainless
Where available: Call 800-383-0130 or go to Woodworker's Hardware website (info, below)

Woodworker's Hardware
PO Box 180
Sauk Rapids, MN 56379
Toll-free: 800-383-0130
Fax: 888-811-9850
Website: www.wwhardware.com

GUESTS :

Shane Kretsinger
Vice President, Operations
Autumn River
We apologize no contact information is available.

Kathryn Vork Waryan
Faux Painter
Graffito, Inc.
3801 Oak Rd.
Minnetonka, MN 55345
E-mail: kvwgraffito@aol.com