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A few months ago we finally decided on a colour for our lounge (Dulux Te Aroha), here it is painted with 6 x 900mm Flatpax Utility Cupboards installed (the last of which was cut down to 635mm to fit the space).
Next step took a long time to resolve. We wanted to cover the doors, preferably with spotted gum veneer to match the TV unit I built earlier in the year. This proved to be a very difficult product to find and after a couple of failed attempts of cutting 3mm veneers from decking boards, I decided to throw money at the problem and remake all 12 doors from spotted gum floorboards.
4 day weekend... lets do this.
I found a local place that sells offcuts and odd lengths of timber for quite reasonable prices so purchased 53 l/m of 75 x 14mm floor boards.
I cut all the boards slightly oversize to allow for any slip or misalignment during glue up.
I made a simple jig for the drill press to accurately drill the holes needed for hinge installation.
The tongues cut from the hinge side slat were used to cap the last board on each panel, 6 boards required for each door (5 full size boards and one slat made from 2 offcuts) left the panel 4 to 5mm oversize.
Big glue up, I used every clamp in the workshop to have all 12 doors done in the same day
The original doors were used to keep the glued up panels flat while drying (the glue doesn't stick to melamine).
Braces required to prevent the door warping over time.
So many holes to drill and countersink
Measure, drill, glue and screw .. over and over
Trimmed the panels to final size on the table saw and then sand and sand and sand
First coat of Penetrol Wood Oil on
Shiny
Bad lighting, but here it is all installed
I completely neglected to take photos while making the counter top which is made from 125 x 12mm floor boards.
More offcuts of the tongues were trimmed down and used for the handles.
Thrilled with the result. Now to rest my aching back...
Hello @ksd050
What a beautiful set of doors. The spotted gum finish really stands out and the fact that you assembled these from offcuts is just awesome. How long did the entire door assembly take? Were there any issues that cropped up during assembly? Would it be possible for you to post a photo of the entire benchtop of the cabinets? I'm sure our members would be keen to have a closer look at your assembly.
Thank you so much for sharing such a wonderful project.
Eric
Time wise there's probably 30 or so hours in this. I got a good rhythm going having to do everything 12 times and setting up a few jigs so no measuring was required for drill positioning saved a bunch of time.
Here's a photo of the finished counter top
Hi @ksd050
Thank you very much for posting that photo of your cabinet countertop and the extra information about your assembly method. I'm sure our members will find your assembly tips useful. I can't help but think that you'll be installing a large TV in front of that sofa.
Again, thank you for sharing such a wonderful project.
Eric
