How to Build Professional Kitchen Cupboards

More than 120 styles of kitchen cupboards are available. The look and feel of your kitchen stems from the style of cupboard you choose. They can also be one of the more costly purchases in your kitchen remodel or upgrade. Machine-manufactured cabinets will cost anywhere from $4,000 to $5,000 and custom-made professional cabinets can cost upwards of $20,000. Another option is to build the cabinets yourself, saving money and giving you the satisfaction of a job well done.

Things You'll Need

• Measuring tape
• 3/4-inch hardwood plywood
• 3/4-inch hardwood lumber
• Panel saw
• Wood glue
• Bar clamps
• Table saw
• Miter saw
• Router
• Rabbeting router bit
• Chisel
• Hammer
• 1/4-inch hardwood plywood
• One piece stile and rail router bits
• Door hinge

Instructions

Building the Carcass

1. Measure the cabinet opening (height, depth and width) to determine the overall cabinet size. Subtract 3/4 inch from the depth measurement to accommodate the face frame. Subtract 1 1/2 inches from the width measurement to make up for the thickness of the sides.

2. Cut two pieces of 3/4-inch hardwood plywood to the height and depth measurements on the panel saw. These will be your sides.

3. Cut two more pieces of 3/4-inch hardwood plywood to the width and depth measurements on the panel saw. These will be your top and bottom pieces.

4. Assemble the carcass using wood glue and bar clamps. The top piece should be flush with the top of the side pieces. Ensure the bottom piece of your cabinet is raised 2 inches from the bottom edge of your side pieces to accommodate the face frame.

Adding the Face Fame

1. Cut four pieces of 3/4-inch hardwood lumber to 2 inches wide with the table saw.

2. Cross-cut two of the pieces to your height measurement. These pieces are called stiles.

3. Determine the front side of your cabinet and glue and clamp the stiles along the left and right face of your cabinet.

4. Cut the remaining two pieces to fit snugly between the stiles. These pieces are called rails. Glue and clamp the rails to the cabinet.

Adding the Back

1. Route the inside of the back of your cabinet, using a rabbeting router bit and router set to 1/4-inch depth.

2. Chisel the routed corners square to accommodate the back.

3. Measure the distance from rabbet to rabbet on either side of the back. Cut a piece of 1/4-inch hardwood plywood to the measured distance. Glue and clamp the back piece to your cabinet.

Building the Door

1. Measure the vertical and horizontal opening between your stiles and rails. Add an additional 1 inch to each measurement.

2. Cut two, 2-inch-wide pieces of 3/4-inch hardwood lumber to your vertical measurement. These will be the stiles for your door.

3. Subtract 4 inches from your horizontal measurement and cut two 2-inch-wide pieces of 3/4-inch hardwood lumber to this measurement. These will be the rails for your door.

4. Route each stile and rail with one-piece stile and rail router bits.

5. Dry-fit your cabinet door and measure the height and width of the opening for the panel. Cut a piece of 1/4-inch hardwood plywood to the measurement. Assemble and glue the cabinet door together.

6. Attach the cabinet door to the cabinet frame using hinges.

Tips & Warnings

• Placing a small piece of cloth in the jaws of the clamps will prevent unwanted scratches.

• When working with power tools, read and understand all safety warnings and user procedures.

• Wear proper protective equipment.

References

• Cabinet Building Basics for DIY'ers
• Kitchen Cabinet Cost

Resources

• Door Making Router Bits