Cabinet Construction 2

8/8/2019 Cabinet Construction 2

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8121 M Kitchens Cabinet Construction:

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As with any cupboard, the basic framework of a kitchen counter is known as the carcase.The carcase may be made in a number of ways including the following.

Solid construction, using solid timber or manufactured boards such as:

particle boards

medium density fibreboard (MDF)

melamine coated board

multi ply.

Combination construction, using a combination of solid panels and timberrails.

Boxes are usually 5 sided with doors on the sixth face.

For more in formation relating to materials go to theseWeb links:

LaminexBrimsboard

CSR

D&R HendersonsPlywood Association of Australia
http://documents%20and%20settings/gcheetham.NSI/Documents%20and%20Settings/Documents%20and%20Settings/gcheetham.NSI/Local%20Settings/Temporary%20Internet%20Files/OLK8E/8121%20M%20Kitchens%20table%20of%20contents.dochttp://www.thelaminexgroup.com.au/downloads/trade_essentials/TradeGuide_Particleboard.pdfhttp://www.brims.com.au/brimsboard.htmhttp://www.chhwoodlogic.com.au/Toolbox/Project/Display/0,11631,7,00.htmlhttp://www.drhenderson.com.au/main.htmhttp://www.plywoodassn.com.au/http://documents%20and%20settings/gcheetham.NSI/Documents%20and%20Settings/Documents%20and%20Settings/gcheetham.NSI/Local%20Settings/Temporary%20Internet%20Files/OLK8E/8121%20M%20Kitchens%20table%20of%20contents.dochttp://www.thelaminexgroup.com.au/downloads/trade_essentials/TradeGuide_Particleboard.pdfhttp://www.brims.com.au/brimsboard.htmhttp://www.chhwoodlogic.com.au/Toolbox/Project/Display/0,11631,7,00.htmlhttp://www.drhenderson.com.au/main.htmhttp://www.plywoodassn.com.au/


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Types of joints:

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Cabinet Construction:

There a many ways to join the components together to form a box. Some traditional and

some more modern forms of construction that have recently been invented for use withflat panel construction techniques:

The best joints are those that involve the use of glue, interlocking joints and mechanicalmeans to hold the joint together.

Typical joints used in carcass construction

include:

Rebates joints (stopped with fillets) Housing joints

Biscuit joints

Dowel joints

Butt screwed

Butt nailed

Loose tongue mitres

Knock down fitting joints
http://documents%20and%20settings/gcheetham.NSI/Documents%20and%20Settings/Documents%20and%20Settings/gcheetham.NSI/Local%20Settings/Temporary%20Internet%20Files/OLK8E/8121%20M%20Kitchens%20table%20of%20contents.dochttp://documents%20and%20settings/gcheetham.NSI/Documents%20and%20Settings/Documents%20and%20Settings/gcheetham.NSI/Local%20Settings/Temporary%20Internet%20Files/OLK8E/8121%20M%20Kitchens%20table%20of%20contents.doc


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The Rebate joint:

The Rebate Joint

has a recess 2/3

the thickness of

material cut intothe accepting

piece.

The stopped rebate

appears as a butt joint

on the front face of thecabinet.

The Rebate Joint

The Stopped

Rebate Joint


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The Housing Joint:

The Barefaced Tongue and Groove Joint:

All the joints above requires glueing and clamping to achieve a quality joint. There are a

range of adhesives that can be used successfully to aid the joint process.

Web links:

AV SyntecThomson White Australia

National Adhesives

Making PVA adhesive

The housing is let in to the acceptingpiece 1/3 the thickness of material.

It may also be in the stopped position

like the rebate joint. 2/3 the thicknesof material is used to form thestopped section

The Housing

joint

The Barefaced Tongue and

Groove joint is let into the

accepting piece 1/3 the

thickness in both directions
http://www.avsyntec.com.au/TB/TB-adh-pva.htmhttp://www.thomsonwhite.com.au/1_adhesives.htmlhttp://adhesives.nationalstarch.com/industry.asp?type=Industry&industry_id=6http://www.kcpc.usyd.edu.au/resources/lectures/PVAglue/SupplementaryMaterial.pdfhttp://www.avsyntec.com.au/TB/TB-adh-pva.htmhttp://www.thomsonwhite.com.au/1_adhesives.htmlhttp://adhesives.nationalstarch.com/industry.asp?type=Industry&industry_id=6http://www.kcpc.usyd.edu.au/resources/lectures/PVAglue/SupplementaryMaterial.pdf


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The Biscuit Joint:

A Biscuit joiner is a woodworking tool used to join two pieces of wood together either on

edge or face to edge.The biscuit joiner uses a small blade (100mm dia) to cut a crescent shaped hole in the

opposite edges of two pieces of wood. An eliptical shaped wooden biscuit is covered withglue, placed in the slot, and the two boards are clamped together.

A biscuit joiner is simple and quick to use.

A biscuit joint is strong. enough for most kitchen manufacturing applications.

Use the largest biscuit that will fit. In most cases this will be a #20 biscuit.

Dry-fit components before gluing to make sure everything fits.

Store your biscuits in a clean dry container. They can absorb humidity from theair and swell.

If you notice your joiner burning or smoking the wood in the slots it's time to

sharpen or replace the blade.

Make the cut: keep firm

pressure on the stops

Clean the joint and

apply the adhesive.


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For more in formation go to:

DIY Article

Biscuit JoinerHandyman Club of America - library

Bring the two parts together

Clamp the joint untiladhesive sets

Make sure to use clampingblocks between the work

pieces and the clamps.

Bring the joint togetherquickly, as the wet glue

makes the biscuits expand.

Wipe off excess adhesive witha damp rag immediately.

Space the biscuits about 250/

300 mm apart on wide joints.
http://www.diynet.com/DIY/article/0,2058,2306,00.htmlhttp://www.woodzone.com/articles/biscuit/biscuit_joiner.htmhttp://www.handymanclub.com/document.asp?dID=828&cID=84http://www.diynet.com/DIY/article/0,2058,2306,00.htmlhttp://www.woodzone.com/articles/biscuit/biscuit_joiner.htmhttp://www.handymanclub.com/document.asp?dID=828&cID=84


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The Dowel Joint:

A dowel is cylindrical piece of timber.

Dowel joints may be used in framing joints (furniture), box joints (cupboards) or

widening joints (panels).Dowels should have a groove down the side to allow any extra adhesive to escape when

the joint is assembled. If the dowels do not have a groove, plane one side flat to achievethe same result.

The ends should be tapered (chamfered) to permit easier assembly and prevent the dowel

tearing the inside of the hole. Again, if the dowels are not tapered, file or sand them to atapered shape.

Widening joint

To obtain a wider piece of timber, two pieces the same thickness may be joined on edgewith dowels.

Hold the two pieces of timber face to face in a vice, with the ends carefully aligned.Square a line across the face edge to mark the centre line of each dowel. Gauge a line

across each of the centre lines in the middle of each edge. Where these lines cross each

other is the centre of the hole.For more information go to: Dowelling

Loose Tongue Mitres:

A loose tongue mitre is a useful joint for joining to wide panels together without a joint

line showing on either face. Care must be taken when machining the joint to ensureenough material is left near the face of the joint to prevent weakness in the joint.
http://opt/scribd/AppData/8121B/Dowel%20joints.dochttp://opt/scribd/AppData/8121B/Dowel%20joints.doc


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The tongue should be no more than 1/3 the thickness of the material being joined.

It is best when the tongue is made from plywood, as this material is more stable thanother materials and provides greater strength to the joint.

With special cutters an interlocking mitre joint can be made:

Having the tongue positioned to

close to the outer edge causesdistortion when the joint is

bought together

Positioning the tongue closer to the

inside of the joint places morematerial on the outside of the joint

reducing deflection or bowing in the

joint.

The joint can be produced on a

spindle moulder or overhead (pin)

router. Cutters need to be sharp


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KNOCK DOWN FITTING

The use of other types of specialist fittings such as theKnock Downfitting has improved

the way we use manufactured boards such as particleboard and MDF.

Knock down Furniture has been around for centuries. Furniture that was too large alwayshad to fit through doorways, up stairs or sometimes through a window as they was the

only means of access. Today with high-rise apartments and offices often the only

convenient means of access is through a lift.

Cam anddowel fittingCover ca

Drilling jig

C

Corne

r

Two part

plastic fitting

Bench topconnectors

Single piece

plastic fitting

Metal clips: this type

is called buttons

Director screw or Confirmat
http://opt/scribd/AppData/Local/Temp/KD%20Fittings.dochttp://www.hafele.com.au/products/furniture.htmhttp://www.hafele.com.au/products/furniture.htmhttp://opt/scribd/AppData/Local/Temp/KD%20Fittings.dochttp://www.hafele.com.au/products/furniture.htm


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Taking bulky pieces of equipment and furniture, whether they are kitchens or

workstations, today means that all the components can be taken to site and assembled.

Components can be pre-finished and assembled quickly with the minimum of equipmentand tools.

Some examples of where they might be usefuls are: Cabinet ends to sides

Tops to carcass

Backs to carcass

Plinth or base to cabinet

Shelves and divisions to carcass

Other websites to visit:http://www.hettich.com.au

http://cornall.com.auhttp://www.nover.com.au/http://www.parbury.com.au/

http://www.hafele.com.au

Construction sequence

Once you have the working drawings and a cutting list you need to decide

how to complete the project. This includes selecting: tools

materials

processes.

Making production decisions means solving problems about how to

complete your project. Decisions you will need to make include how to: cut materials to length and size ( cutting lists and cutting patterns)

form trenches for certain types of joints

make rebates and grooves sand and prepare the surfaces for assembly

assemble the machined components finish the product.

By making these decisions you form a plan or procedure. The whole

production process can be represented by the following diagram.

(Insert production cycle)
http://www.hettich.com.au/http://www.cornall.com.au/http://www.nover.com.au/http://www.parbury.com.au/http://www.hettich.com.au/index_au_2352.htmhttp://www.hettich.com.au/http://www.cornall.com.au/http://www.nover.com.au/http://www.parbury.com.au/http://www.hettich.com.au/index_au_2352.htm


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Typical construction sequence

A typical construction sequence for a fitment is:

identify appropriate tools/equipment select materials and accessories

plan the machinery

cut to size as per cutting list prepare joints

drill all necessary holes

shape components (if required) select adhesive

assemble components

apply finish (if applicable)

fit up (hardware etc)

Assembling carcases

After joints have been prepared some planning must take place before

assembly of cabinets or carcases (the outside frame of a piece of furniturewithout doors or drawers fitted).

Fitments are usually designed with loose tops and bases. Sometimes fitments

have sub-assemblies that would be better to assemble first beforeattempting assembly of the whole cabinet/carcase. The following diagram

shows three sub-assemblies of a cabinet.

The subassemblies in this diagram are the:

top


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shelves

base plinth or kicker

The diagram below shows the finished item.

Before assembling a carcase or cabinet as much work as possible should be

done on the parts. Some examples are shown below.

Holes drilled for adjustable shelves.

Shoulder sizes checked; eg lengths

of rails, shoulders for stopped

housings.

Panels fine sanded both sizes.

Timber or metal drawer runners

fixed.


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Holes drilled for fixing top.

Hinge mounting plates fixed.

Stopped rebates or housingssquared out.

Trial (dry) assembly and check.

Checks after assembly

The two main checks of the sub-assemblies of completed carcase are:

1. wind

square


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To hold the carcase square when it is in cramps and after checking wind andsquare the backpanel can be fixed in place. If no backpanel can be fitted at

the time, small triangles of plywood, MDF board or similar can be fitted tothe back corners as temporary bracing. A diagram of temporary bracing isshown below.

Installing shelves

Shelves divide a cabinet into levels for storage. If your shelf is to be fixed inbetween divisions it is wise to assemble this section first. Shelves may be

fixed or adjustable. Fixed shelving can be installed several ways. You can

use: dowels

screws

nails

housing joints.Adjustable shelving is more flexible than fixed shelving. However, there is

more preparation involved particularly if there are many shelves in the

project.Before the project is assembled it is advisable to drill the appropriate holes

for the shelf supports. It is a good idea to make up a pattern for marking

each hole if a series of holes need to be marked and drilled. This pattern isalso called a marking jig The diagram below shows a marking jig laid out on


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an end panel ready for drilling.

Cabinet Construction 2

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