Note: Click here for a materials list and complete instructions without images.
Materials for the Complete Job:
Table saw
Miter saw
Jig saw
Pneumatic finish nailer and nails
Compressor and hose
Wood glue
Wood putty
Tape measure
Framing square
Speed square
Saw horses
Masking tape
Utility knife
Straightedge
Clamps
Spring loaded center punch
Cordless drill
Router
4' level
Paintbrush
Tack rag
Sandpaper
Sandpaper block
Stain (golden pecan)
One hour finish (sealant/polyurethane) Cost and Time: The cost of re-facing old kitchen cabinets is approximately $5,000, and this project should take approximately 18 hours over two days. Difficulty Rating: It's rated a 3 on a scale of 1 to 5. Day Two - First you'll need to put the hinges on the doors.
Tip: Take an extra hinge to use as a spacer. Line it up to the bottom edge of the door and take another hinge and line it up right next to the "spacer" hinge (figure A), and you'll know exactly where your hinge should be. - Use a jig so you can easily find the spot to pre-drill the holes for the screws. Place the jig on the bottom of the cabinet; attach it (figure B) and this way you will ensure the same position for each hinge on each door. Host Paul Ryan used a self-centering bit, which you just push in. It not only centers itself in the hardware; it sets the right depth so you won't drill through the door.
Aesthetic Tip: Most door grains will have a pointed tip (figure C). Be sure to install the doors with the tip either up or down on all the doors. Be uniform either way, but it's generally more pleasing for the tips to be pointing down. (The tips on the doors for this particular project are pointing down.) - Hang the doors, then level them and readjust hinges if necessary. Leveling the doors can be a challenge. They don't always come out perfectly even. You may have to readjust the hinge screws on the inside cabinet edge to synchronize the doors.
Note: No cabinet door would be complete without shock absorbers. What's a shock absorber (figure D) you may ask? It's a small, white mount that makes the doors close smoothly. It works just like the shocks in your vehicle. These work especially well with cabinet doors that have glass. Tip: Remember to use your original kitchen-cabinet drawing as a guide. The doors should be numbered to correspond with the drawing. - The drawer fronts are next. You can use your old boxes, but for our show we ordered new boxes.
- If you do order new drawers, lay one of the new drawers on the "old" drawer front (figure E) to get the proper measurements. Take equal measurements on the top, bottom and two sides, and once you have that distance measured, just attach the new front panel, drill pilot holes and clamp it together while you do the attaching. Then screw it on from the back.
- Put new drawer slides on the inside boxes.
Note: There's a huge selection of drawer slides on the market. A lot of older homes have the 3/4-extension slides. Your kitchen remodel may allow you to upgrade to a full extension glide (figure F) that will last a lot longer. - To attach all the drawer and door hardware, host Paul Ryan created an adjustable jig that allowed him to align each piece of hardware.
- Attach all hardware and you're done!
RESOURCES :
Cabinet Doors, Drawer Fronts, Hinges, Drawer Slides and Veneer
Cabinet Doors
Model # Oak
Style: Berkshire
Drawer Fronts
Model # Oak
Style: Solid Oak
Hinges
Model # Bkhinge
Color: Burnished Brass
Drawer Slides
Model # KV1284
Veneer
Model # Oak
Type: PSA
Woodcabinetdoors.com
Website: www.woodcabinetdoors.com
Rockler Woodworking & Hardware Products
Book: Refacing Cabinets
Catalog # 90595
PSA Veneer 24x24
Catalog # 61269
Color: Red Oak
PSA Matte Laminate
Catalog # 32731
Color: White
2-14" Blum low profile drawer slides
Catalog # 34835
Five 22" Blum low profile drawer slides
Catalog # 34876
Self-centering Bit-Set
Catalog # 34537
Fuller Bit & Countersink Set
Catalog # 70441
Stop collar for above
Catalog # 49429
Stop Collar for above
Catalog # 49437
40 knob pulls
Catalog # 35172
JIGIT template and Punch for knobs
Catalog # 35172
221' lin/ft of 1/4"x2" Solid
Catalog # Stock
Color: Red Oak
65' lin/ft of 1/4"x6" Solid
Catalog # Stock
Color: Red Oak
20' lin/ft of 1 x 8 Solid
Catalog # Stock
Color: Red Oak
Smove Cabinet Door Shock Absorber
Model # 39921
Smove Test Block
Model #: 39930
Rockler Woodworking & Hardware
Website: www.rockler.com
GUESTS :
John and Mike Lepak
Woodcabinetdoors.com
4728 Rice Lake Rd.
Duluth, MN 55803
Tollfree Phone: 800-732-0309
Fax: 218-727-6511
Email: info@woodcabinetdoors.com
Website: www.woodcabinetdoors.com
CFO & COO
Dennis Wagner
3639 Nicollete Ave.
Minneapolis, MN 55406
Phone: 612-827-3948
Fax: 612-822-7818
Email: 714@visi.com
General Contractor
Al Wolford
Rockler Woodworking & Hardware
4365 Willow Dr.
Medina, MN 553401
Phone: 763-478-8334
Fax: 763-478-8393
Email: awolford@rockler.com
Website: www.rockler.com
Supervisor Technical Support
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