Build your own kitchen cabinets

131 Pages·2003·20.089 MB·English

by  Danny Proulx

70641 CM KITCHEN POB New 9/3/08 2:48 PM Page 1
ES
WOODWORKING DE
ITCO BUILD YOUR OWN
I
ON
BUILD YOUR OWN ND
KITCHEN
B
KITCHEN CABINETS!
U
I
L
D
CABINETS

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O
U
You don’t need a showroom full of equipment or R
expertise in calculus to build your own kitchen cabinets. S E C O N D E D I T I O N
O
In fact, Danny Proulx’s concise, easy-to-follow instructions enable you to create
W
incredible kitchens with just a few power tools—a table saw, circular saw,
router and drill. N
Completely revised and updated, Build Your Own Kitchen Cabinets,
K
Second Edition, provides start-to-finish guidelines for crafting upper and lower
cabinets, plus practical information on kitchen design, material selection and I
tool shortcuts. T
Proulx’s instruction is practical, easy to understand and time-tested, refined C
in his own shop, and taught by him in countless seminars and workshops. You’ll
H
learn how to plan, design, construct and install your own complete handmade
E
kitchen, from simple cabinets and over-the-sink cupboards to lazy-Susan shelv-
N
ing, stemware storage and more:

• Combine the beauty of traditional face-frame cabinetry with the strength C
and simplicity of European cabinetry and hardware A
• Build drawers, pull-outs and flip-outs to maximize storage space
B
• Use European hinges, adjustable legs and other specialized hardware to
take the guesswork out of construction and installation I
N
• Use simple butt joints to build strong cabinets quickly
• Customize your cabinets’ looks with a variety of door styles, countertops E
and finishes T
S
Page after page, Danny Proulx proves that you can build your own beautiful
kitchen cabinets.
P
LOOK FOR THESE
R
OTHER FINE O
U
TITLES FROM
L
DANNY PROULX UK £18.99 X
70641
EASY-TO-FOLLOW INSTRUCTIONS
FOR PLANNING,CONSTRUCTING AND
INSTALLING CABINETS AND ACCESSORIES
N
A
E
POPULAR
WOOD DANNY PROULX
WORKING
BOOKS
3333449999 ddeessiiggnn pp000011--001155..iinndddd 11 1122//2277//0066 1111::2255::4433 AAMM
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 1
BUILD YOUR OWN KITCHEN CABINETS
SECOND EDITION
8-1
FPO
159%
DANNY PROULX
POPULAR
WOODWORKING
BOOKS
CINCINNATI, OHIO
www.popularwoodworking.com
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 2
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Cincinnati, Ohio, 45236. Second edition.
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ccuurrrreenntt aatt tthhee ttiimmee ooff ppuubblliiccaattiioonn aanndd aarree ssuubbjjeecctt ttoo tion on more resources for woodworkers.
tion on more resources for woodworkers.
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Other fine Popular Woodworking Books are available from your
aanndd mmuusstt bbee tteemmppeerreedd.. UUnntteemmppeerreedd ggllaassss sshheellvveess mmaayy Other fine Popular Woodworking Books are available from your
local bookstore or online retailer.
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Library of Congress Cataloging-in-Publication Data
Library of Congress Cataloging-in-Publication Data
Proulx, Danny, 1947-
PBrouuilldx , yDoaunr noyw, n1 9k4i7tc-hen cabinets / by Danny Proulx.— 2nd ed.
Buipld. cymou.r own kitchen cabinets / by Danny Proulx.-- 2nd ed.
Inclupd.e csm in.dex.
InIcSlBuNde-1s 3i:n 9d7e8x-.1-55870-676-7 (pbk. : alk. paper)
IISSBBNN -11-35:5 987780--16-75568-37 0(-p9b2k0.- 1: a(ElkP. UpaBp)er)
1I.S BKNit-c1h0e: n1 -c5a5b8in7e0t-s6.7 26.- 3 C (apbbink.e t: walokr.k p. a Ip. eTri)tle.
1T. T K1i9t7c.h5e.Kn 5c7a bPi7n6e t2s0. 023. Cabinetwork. I. Title.
6T8T41.917'6.-5-.dKc5271 P76 2003
684.1'6—dc21 2002152424
2002152424
ACQUISITIONS EDITOR:Jim Stack
ACQUISITIONS EDITOR:Jim Stack
EEDDIITTOORR::JJeennnniiffeerr ZZiieegglleerr
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CCOOVVEERR AANNDD CCHHAAPPTTEERR LLEEAADD PPHHOOTTOOGGRRAAPPHHYY BBYY::Michael Bowie
of MLiucxh aPehl oBtoogwriaep ohfy Lux Photography
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70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 3
Once again my “team” has come through to help me about the author | Danny Proulx has
been involved in the woodworking field
complete this book. Thanks to my wife, Gale, for her
for more than 30 years.He has operated a
support and helping hand when needed, and to Jack custom kitchen cabinet shop since 1989.
Danny also teaches full-time and continu-
Chaters, who is always ready to help. They are two
ing-education students at Algonquin Col-
lege in Ottawa,Ontario.
important people.
He is a contributing editor to Cabinet-
Thanks also to Michael Bowie, who has Makermagazine and has published articles
in other magazines such as Canadian Home
been the primary photographer and photographic
Workshop,Canadian Woodworking,Popular
knowledge source for all my books. As a photogra- Woodworking,Woodshop Newsand Canadi-
anHomes and Cottages.
pher and person, Michael is in a class of his own; His earlier books include The Kitchen
Cabinetmaker’s Building and Business Man-
he has a special gift.
ual,How to Build Classic Garden Furniture,
The illustrations were revised and became Smart Shelving & Storage Solutions,Fast &
Easy Techniques forBuilding Modern Cabi-
works of art that were light-years in quality above
netry,Building More Classic Garden Furni-
ture,Building Cabinet Doors and Drawers,
the original drawings. Len Churchill is a talented
Build Your Own Home Office Furniture,Dis-
illustrator with a unique style that few can match. play Cases You Can Buildand Building
Woodshop Workstations.
Len is a real pleasure to work with and always gives
His Web site address is www.cabinet-
more than requested. making.com,and he can be reached by
e-mail at [email protected].
The staff at Popular Woodworking Books is
my support team, and I’m lucky to have such a tal-
ented and dedicated group of professionals. Editor
Jim Stack and all the other talented and helpful
members of the PW team are ready to help at a
moment’s notice. Thank you!
Thanks are also due to all the readers of my
books who have sent pictures of completed projects,
comments, suggestions and tips of their own for me
acknowledgements | Many suppliers
to use. I truly appreciate your time and efforts.
have contributed products,material and
technical support during the project-build-
ing phase of this book — companies like
Delta,Porter-Cable,Exaktor Tools,Blum
and many others.
I appreciate how helpful they’ve been
and recommend these companies without
hesitation.A complete list of suppliers is
included at the end of this book.
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 4
table of contents
INTRODUCTION. . . 6 chapter seven
BUILDING ISLANDS
SUPPLIERS. . . 126 AND PENINSULAS |
page 64
INDEX. . . 127
chapter eight
COUNTERTOPS |
page 68
chapter one
DESIGNING AND BUILDING YOUR
chapter nine
OWN KITCHEN CABINETS | page 8 MAKING CABINET DOORS
AND DRAWERS |
page 74
chapter two
KITCHEN CABINET
chapter ten
ANATOMY | page 20 BUILDING FRAMELESS
CABINETS |
page 84
chapter three
BUILDING UPPER FACE-FRAME
chapter eleven
CABINETS | page 24 FINISHING CABINETS | page 104
chapter four chapter twelve
BUILDING BASE FACE-FRAME MATERIALS LISTS AND
CABINETS | page 38 CUTTING PLANS | page 108
chapter five chapter thirteen
PANTRY AND MICROWAVE SHOP ASSEMBLY
TALL CABINETS | page 54 PROCEDURES | page 114
chapter six chapter fourteen
SPECIAL TRIM, ACCESSORIES CABINET INSTALLATION |
page 120
AND CUSTOM CABINETS |
page 58
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 5
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 6
introduction
T
his book is a revision pean innovation used because of its seem to be reverting to earlier times
of my original edition strength, durability and ease of adjust- when the kitchen was a large meeting
published in 1997. It ment. The building system is logical and place for family and friends, as well as
contains updated extremely adaptable to all situations, and a place to prepare meals. Consequently,
information about hard- the end result equals the best kitchen over the last few years the emphasis
ware, sheet material and cabinets available on the market. seems to be moving toward larger
techniques. We’ve printed the book in Building kitchen cabinets requires kitchen and kitchen/family room combi-
color and improved the illustrations. basic woodworking skills along with nations. New homes are being designed
The improvements in this revised text some of the power and hand tools most with larger kitchens and family or great
are in many ways largely due to woodworkers own. Power tools include rooms, as they are sometimes called, to
comments I’ve received from readers a table saw, circular saw, router and meet those desires. Renovation projects
over the last five years. drills. Tools such as a radial-arm saw, involving the kitchen require more
Kitchen cabinetmaking, like many power screwdrivers and power sanders space be allocated or, at the very least,
other skills, requires nothing more than are always handy but not absolutely the use of light–colored or natural wood
attention to detail and patience. This necessary. Obviously, the more tools cabinets, to make the room seem larger.
skill is learned and improved upon with you have and the more experienced Most of the kitchens in the homes of
practice and, I believe, well within the you are with these tools, the easier it the fifties and sixties were designed
scope of most home woodworkers. will be to build cabinets. However, the with no-nonsense, dark cabinets, simply
The kitchen cabinetmaking style end result is dependent on the care and as a place to quickly prepare a meal and
detailed in this book is a simple, attention to detail that you put into the leave. Now everyone wants to “hang
straightforward style used by many project and not primarily on the tools out” in the kitchen. Remember the last
cabinet manufacturers, with some you own. time you had family and friends over for
minor variations. Common dimensions The most important piece of advice a meal? Where did everyone congre-
such as cabinet depth, height and that I can give anyone involves the gate? If it’s anything like my place, all
width, are detailed, as well as simple planning and cutting of the cabinet the guests were in the kitchen. We don’t
rules to calculate door widths. As you parts. Take your time to plan the want a dark dungeon anymore. Most of
will see in later chapters, the normal cutting process and accurately cut all us want a bright, airy, warm and com-
depth for a base cabinet is 24", upper the parts to the correct size. The as- fortable room to prepare meals, chat
cabinets are approximately 12" deep, sembly and final finishing will be simple with friends, make crafts or just relax in
and the space between the upper and if the cabinet pieces are accurately cut. a cozy surrounding.
lower cabinet is from 16" to 18". I have been involved in many areas From a personal point of view, I
This building style was adapted from of renovation work over the last 30 agree: Nothing is nicer than a large,
many sources. Primarily, it’s a blend of years, including home building, addi- bright, cozy kitchen. From a business
the best features of European– and tions, basement finishing and kitchen point of view, I couldn’t agree more;
North American–style cabinetry. The and bathroom projects. The range has millions of older homes are waiting for
carcass, or cabinet, is built with 5⁄8" or 3⁄4" included building and installing a simple a kitchen renovation. Many of us are
melamine-coated particleboard (PB) or bathroom vanity to building a complete saving for the day when we can begin
veneered sheet materials. A hardwood home. Over the last 5 years my specialty a kitchen renovation project.
face frame is installed, taking the place has been writing about kitchen cabinets To illustrate my point about the
of the European method of edge tape and the business of cabinetmaking. I also popularity of kitchen renovations, take
on the exposed PB edges. Adjustable teach a kitchen cabinetmaking course a look in the yellow pages of the phone
legs are installed on the base cabinets at a local college, so I’m exposed to the book under “Kitchen Cabinets” and
to maximize the cutting from a sheet hands-on construction techniques. count the number of companies in your
of PB and allow for easy installation. Today the focus of activity in the area. As well, look at most of the popu-
The hidden hinge is another Euro- home is the kitchen or family room. We lar how-to shows on television and take
6
70626 I KITCHEN pg 1-19 New 9/3/08 2:04 PM Page 7
note of the time given to kitchen proj- Today, modern kitchens have many detail and accurate cutting. Assembly
ects. It’s a popular topic with most appliances, work-saving devices and of all the parts is simple when they are
homeowners. Almost every time I meet accessories that are a must in every sized correctly. With a little time and
someone new and he or she asks what kitchen. Pasta makers, bread makers, effort your final product will be beauti-
I do for a living, the first comment is dishwashers, automatic coffeemakers ful. With this book you can build your-
“That’s interesting. You know, I really and so on all require space in the self a beautiful, quality kitchen and stop
must do something about our kitchen.” kitchen. Modern cabinets are fitted there, or you can build for friends and
Years ago kitchen cabinets were built with drawer pullouts, lazy Susans, pull- family to recoup your costs. If you real-
without too much thought about interi- outs in lower cabinets, multiple drawer ly enjoy the building process, you can
or use and function. Shelves were fixed assemblies, wall ovens, built-in cook- open your own part-time or full-time
in place and finished with a coat of tops and all the other features that kitchen cabinetmaking business. The
paint. Most cabinets required the home- make today’s kitchen an exciting place choice is yours. There certainly is
owner to paint the kitchen walls that to work and gather with friends. enough work to go around for the
could be seen inside the cabinets and Building kitchen cabinets is not diffi- quality kitchen cabinetmaker.
cover the shelves with paper. cult. All that is required is attention to
7
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8