DIY Network

Custom Cabinet Installation From "DIY to the Rescue" episode DTTR-403F

Cabinet Installation

Materials:

Table saw
Circular saw
Straight edge 24" long minimum
(2) clamps
Pencil
Tape
Sandpaper (80-grit)
Air compressor
Blower tip (to clean off sawdust prior to painting)
Drill and bits
Trim air stapler
Stud finder
Level
Paint rollers, trays, and brushes

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	Figure A
	Figure B
	Figure C

Before Getting Started: In this example, all doors will be constructed of 3/4" oak plywood. All cabinet openings 24" wide or less will get one door hinged either on the right or left.

All cabinet openings wider than 24" will get two doors, hinged on each side. Cabinet doors that are 48" tall or less will have two hinges per door. Cabinet doors that are taller than 48" will have three hinges. Hinges are surface mount spring loaded cabinet
hinges. The hinges mount to the door with three screws and then mount to the cabinet with two screws.

The process: (Using a cabinet with a 21" x 80" opening as an example)

1. Measure each cabinet opening and add 1/2" to the width and height (1/4" for each side) for the door measurement.

2. Using the table saw, rip a 21-1/2" wide piece from a full sheet of 3/4" plywood.

3. To cut the door to length in a perfectly straight line, clamp a straight edge across the door so the saw blade is at the 80-1/2" mark. Set a straight edge at 1-1/2" back from this mark to allow for the 1-1/2" width of the shoe on the circular saw. (Note: Using this jig is a simple way of making a perfectly straight cut without having a large radial arm saw.)

4. Once it is cut, the door edges need to be lightly sanded.

5. Using one hinge as a template, mark the three holes per hinge to be drilled using a pencil. For this tall door, hinges will be located in the exact center of the 80-1/2" length, 8" down from the top and 8" up from the bottom. On the shorter (less than 48") doors, hinges will be 8" from each end. Drill three pilot holes per hinge, being careful to drill less than the 3/4" thickness of the wood so you don't go through.

6. Next step is painting - One coat primer on all surfaces and one coat semi-gloss latex on the exterior face and edges. Paint will be applied with a 9" roller. Prime the outside face and all four edges first, after dry then flip over and prime the inside, then after that is dry flip back over and paint the outside face and all four edges with semi-gloss finish paint. Use a semi-gloss paint tinted to match the tan floor tiles. Primer will be tinted the same color.

7. Once the paint is dry, hinges will be mounted to the door with three screws into the pre-drilled holes. The door will then be mounted to the cabinet by holding in position, marking hole locations, drilling pilot holes and then attaching with screws.

8. Handles will mount high on the base cabinets, in the middle on the tall cabinets and low on the upper wall cabinets. Install the handles last to avoid any confusion as to where the handles go in relation to each cabinet.