DIY Network

Urban Conversions (2 of 4): Flat-Pack Cabinet Assembly From "Kitchen Renovations" episode DKTN-306

	Host Paul Ryan and our homeowner (Erica) take an old 1920s restaurant kitchen that had been empty for years ...
	and turn it into an eye popper ...
	without losing its sense of history.
	In this second part of Urban Conversions, host Paul Ryan helps the homeowner put together and install flat packed cabinets ...
	and build a large table.

Materials for Cabinet Installation --

Safety glasses
Ear protection
Hammer
Phillips head screwdriver
Flat head screwdriver
Tape measure
Level
Quick clamps
Drill
Union bolts
Containers: used to separate hardware included in Flat Pack
Ramset
Table saw
Panel adhesive
Clamps

Materials for Building Table --

1/2" hammer drill
5/16" carbide-tipped masonry bit
Steel studs and track
1-1/4" Perma-Grip anchors
Legs
Table base
Wood glue
Brush
Chisel
Toothbrush
Rag
Ratchet straps
Biscuit joiner
Biscuits
Bar clamps
Roller stand
Circular saw

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H
	Figure I
	Figure J

The cabinet boxes are unpacked and organized. Paul and Erica start the assembly system that uses cam locks and posts. The backer and feet are attached.

1. Instructions come with the cabinets (figure A) that will give you step-by-step details in how to assemble the cabinets.

2. Unpack the boxes and check to make sure all the parts are there.

   Tip: Most flat pack cabinets come with a lot of hardware. It will make your job much easier of you place the parts in individual containers (figure B) to organize the parts. It will make assembly easier and you won't lose anything.

3. The heart of the connection system is a two-part cam lock system that consists of a cam and a locking bolt (figure C).

4. Screw the posts into one side of the cabinet (figure D) and the cam will go into the other side. There is an arrow that will show you the correct way to install the cam (figure E).

5. Slide it into place (figure F) and then use a screwdriver to turn it (figure G) and it will pull it nice and tight to make it secure.

6. Install the cabinet pieces side to side and then top to bottom.

7. To align the components you tap a series of wooden dowels along the length of the panel (figure H).

   Tip: Don't overdo the dowel tapping. Easy does it!

8. You just repeat the same process -- screw the posts into the holes designated in the instructions, slide the panels over the post lining up the dowels, and, after all the cams are in place, tighten them with a screwdriver.

9. In the upper corner, screw in steel brackets (figure I) that will provide strength for the cabinets.

10. After the cabinets are put together, you need to check to see if they are square. Just measure corner to corner and see if the figures are the same.

11. Attach the backer by using the nails provided (figure J).

12. The boxes also come with adjustable feet that insert in the holes in the bottom. These allow you to raise or lower the cabinets once they are in place. The standard height of a cabinet is 36".

In the next segment, the cabinets are installed.

RESOURCES :

Cabinetry
Brand name: IKEA
Style: Hallrum door and drawer fronts, design by Mikael Warnhammer
Rationell drawers, fully extended with interior wire baskets
Color: Dark-stain eucalyptus veneer
Where available: Visit the IKEA website or call their toll-free number, below, for more information.
IKEA
Website: www.ikea.com

Table Legs and Accessories (Classic Designs by Matthew Burak)
Product: Spiral Kitchen Leg
Model #: 303-XL36SP
Color: Cherry

Product: Custom Mortising
Model #: CM01

Product: Custom Length Aprons
Model #: A400
Color: Cherry

Product: Applied Bead Moldings
Model #: M660
Color: Cherry

Brand name: Classic Designs by Matthew Burak
Where available: Call 800-843-7405 or visit Classic Designs website, link below.
Classic Designs by Matthew Burak
Website: www.tablelegs.com

Wood for Tabletop
Brand name: Reclaimed Douglas Fir, Lumber
Where available: Visit the Manomin Resawn Timbers website, link below.
Manomin Resawn Timbers
Owner, Doug Laurent
15152 Freeland Avenue
Hugo, MN 55038
Phone: 651-464-1771
Fax: 651-464-3907
Website: www.mrtimbers.com