DIY Network

The Inside Job: Installing Pantry Drawers Got lots of kitchen stuff and no place to store it? Got a pantry that could use some organization? Consider building pantry drawers. HGTV's Carter Oosterhouse shows how. From "The Inside Job" episode DISJ-104

Gutting a kitchen and starting from scratch would take most contractors weeks. But master carpenter Carter Oosterhouse and his team from HGTV's Carter Can have just three days to get it all done. For this makeover, Carter and crew modernize a kitchen space with all new flooring, cabinets, countertop, and a custom storage space.

Before

After

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	Kitchen pantry, BEFORE
	. . .and AFTER.

Pantry Overhaul: Installing Pantry Drawers

Following is a summary of the steps in the updating of the kitchen pantry, installing new pantry drawers, as seen in this installment of The Inside Job.

Tools:

orbital sander with 150-grit sandpaper
nail gun
handsaw
pocket hole jig
level
tape measure
drill
clamp
screwdriver

Materials:

wood glue
hex head pocket hole screws
birch (2'x2' sheet of 1/4")
maple (4'x8' sheet of 3/4")
solid maple lumber (6 feet of 1-1/4")
galvanized steel (2'x2')
double-sided tape
drawer slides and guides (2 of each)

Steps:

1. Measure the dimensions of the space the drawers will fit into and cut the maple pieces appropriately — two that will measure the depth of the space and two that will be the width. Be sure to sand the edges for a smooth finish.

	Figure A
	Figure B
	Figure C

2. You will need to make a dado cut close to the bottom of each piece so that the drawer bottom will slide in snugly. To do this, run each piece through a table saw with saw depth set at 1/4". Move the saw 1/8" wider and run the pieces through again (figure A).

3. Glue alone won't hold the pieces together, so you will have to insert screws with the help of a pocket jig, which creates recessed holes that are easy to cover up (figure B). Drill at least four evenly spaced pocket holes on the outside of each drawer piece since the drawer will need to hold a lot of weight in the kitchen and needs plenty of support. Be sure the dado cut is on the inside!

4. Next you will start the process of securing the pieces together. Place a moderate amount of wood glue along two connecting edges, which will form the back and side of the drawer. Hold the edge pieces together so they meet at a corner, beginning with the back and two sides. Be sure to place a clamp at the corners so they hold together while you are working and allow the glue to set. The pointy end should be stuck into the pocket holes themselves for greater stability (figure C).

5. Once the corners are lined up flush, screw the hex head screws into the pocket holes. Continue this process until the back piece and sides are secured.

6. Next, slide the wood bottom – birch is a good option – through the dado cuts and into place. Consider grain direction when placing the bottom so that you will be looking down the grain when pulling out the drawer.

7. Glue the edge of the front drawer piece and secure it. At this point, it should fit in nice and tight without much use of the clamp. Fasten the remaining screws.

8. Attach one drawer slide to the drawer and screw it into place. Attach the corresponding guide to the surrounding cabinet at the same height as the slide so the drawer will fit in nicely. Repeat this process for the other side.

9. Next, it's time to make the drawer face frame. Cut four pieces of solid maple into two rails (on the top and bottom of the face frame) and two stiles (on the sides of the face frame). Keep in mind that the two rails will fit inside the stiles around the perimeter and will overhang ½" around the entire perimeter so there is something to grasp when pulling out the drawer.

	Figure D
	Figure E

10. Using the pocket jig, drill at least two holes on each side of the rails to secure them to the stiles. Glue the pieces together. Fit the clamp along the corners if necessary and screw them in tightly. Put the frame aside until after the drawers are installed inside the pantry.

11. To give your drawers a more contemporary feel and to hang magnets, try adding galvanized metal to the front, underneath the face frame you've just constructed. Measure and cut the galvanized metal to fit the front of the drawer. The cuts do not have to be entirely precise since they will be covered with the wood face frame. Buff the metal using an orbital sander to create a more abstract, industrial look (figure D).

12. Install the drawers by fitting the drawer slide inside the glide and pushing the drawer into place.

13. Now it's time to attach the metal and frame to the drawer face. Place some strips of double-sided tape on the back of the metal and stick it to the front of the drawer.

14. Once the metal face is on, hold the wood face frame to the drawer on top of the metal (figure E). Hold a level on the top of the frame to make sure everything is nice and flush, then secure the frame in place with a nail gun. Nail from the inside of the drawer so that the nails aren't visible from the outside. Now your drawer is ready to hold your kitchen stuff!

The kitchen, BEFORE the makeover.

The kitchen, AFTER the makeover.

RESOURCES :

Countertop: Slate Black paper-based countertop
Richlite Company
www.richlite.com

DIY Green Solution: Paper-Based Countertops
Richlite's paper-based countertops are a great alternative to stone and plastic surfaces. They are comprised of pulp from trees that are harvested in sustainable forests with closely-managed environmental mandates such as habitat conservation. They come in a variety of colors and options and are mostly stain resistant, scratch resistant and heat resistant.