April 2012                                                 Click on (most) images for a larger view.

After almost a month off to take care of other things, we are now getting back to building cabinets!  The downstairs bathroom vanity is the first project. We chose it because we felt it would get us back in the swing of things. We did not anticipate the fun we would have with all the angles on this custom neo design. You often hear stories of how the builders grumble at the designers for a concept that is hard to manifest. Well, if you wear both hats you can grumble at yourself of take pride in a complex job well done using simple tools and equipment.

       
       
The base frame gets us started, the tape helps to visualize the cabinet dimensions The neo had chopped corners to maximize usable space. This provided a unique opportunity for a clean fir to pine transition but it required much mocking up to get the dimensions right. Custom jugs on the table saw to accommodate the steep angles
       
Clamps and straight edges allow for wide angle cuts Dry fitting the components is critical to insuring that dimensions are true. To accommodate the drawers, walls had to be parallel and of course the calculated dimensions didn't always work out precisely.
       
Adjustments had to be made and some trimming was in order While I was busy scratching my head, Laura prepared the glass block and cut the shims for later installation in the shower.
       
Using braces to hold the four walls in place allowed for final and precise alignments and adjustments. Marking the paper-face panels to position the screws Gluing and screwing paper-face panels in place. We used white painted paper-face in the back of all lower cabinets for contrast and to save money.
       
Starting to look like a cabinet... Cali, our mascot needs kisses... Placing an end on our wall blocks allows us to use them as guides when dry fitting the cabinet on location. So far, so good.
       
Triangle corners provide stiffness and support for the trim. The laminated project pine allows for large trimmed sides
       
slightly oversize for alter adjustment painting the glass blocks Douglas Fir has been milled and is ready for fitting and attachment.
       
Our water soluble construction adhesive is fantastic for this task. It acts as a filler as well and in two days it is hard enough to sand.
       
sanding edges and the face makes for a clean look Framing makes all the difference. Dry fitting again to line up with the tile pattern on the floor.
       
Adjusting shim thickness allows us to determine the final position of the cabinet before scoring the trim to match the wall contour...
       
Making sure the sanding is square And that everything is on a consistent plane, front and top. Drawer Slides accommodated...
       
...for short side drawers Calculating the sink cutout. "Mounting strips" with full coverage scoring counter to accommodate
wall contours
       
The paper-face support strips underlay the 3/4" counter All materials in place allows us to calculate final sink position
       
First we cut out the support strip and once that is confirmed good we cut out the plywood counter. Counter comes back in the workshop and we dry fit the counter trim around the exposed edges.
       
The further you get into a job the more is at stake so no messing up. Clamps and our magic glue make fasteners in this exposed location unnecessary.
       
When sanding the surface we were careful to orient the belt towards the center of the piece and made sure to maintain a flat surface for the Formica. No rounded edges allowed.
       
Yet another dry fit to make sure everything gets along and looks clean. Straight edge and skill saw set real shallow allows clean trimming of Formica sheets at any angle. A black market helps to hide our joints.
       

Water based contact cement is a joy to work with but there is a trick.

Pay close attention to room temperature...

Under 68 degrees and the timing doesn't work, so keep things warm.

       

Mounting and rolling is a two person job...

Come see the video and maybe subscribe to our YouTube channel!

       

Careful hand sanding of edge gets rid of any burs and cleans the joint.  Use a block to sand to get a clean, flat sand, not a sanding sponge which could round the sharp edges.

Plunge bit lets us cut out the sink hole    
       

Final fitting before cabinet is off to the finishing room to get stained and varnished!

And off we go to the next set of cabinets...

       

Go back to last month...

   

 

       
       
       

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