How to Build a Corner Kitchen Cabinet (July 7, 2009)

A kitchen corner cabinet is essential in using as much kitchen space as possible. The tricky part about this type of cabinet is the face frame. For a good, custom fit, it is a good idea to determine the frame's width after the shell of the cabinet has been installed. This will eliminate gaps between the wall and cabinet.

Ready the End Panels



1. 
   
   Step 1
   
   

   Place the 2 pieces of 23-by-34½-by-¾-inch plywood on a work table. These are the end panels of the corner cabinet. Measure 4 inches up from one end and make a mark. Place the framing square on the mark and draw a line across the 23-inch width of the end panel. Repeat this for the other end panel. This is for the cleat, which will support the bottom shelf. If it helps, write the word "bottom" under the line to label the bottom of the end panel.

   
   
2. 
   
   Step 2
   
   

   Make a mark on the line from the previous step 4 inches from the edge. From that mark, draw a perpendicular line down to the bottom edge of the end panel. This will give you a 4-by-4-inch square. Cut this out with the jigsaw. Repeat this for the other end panel. This is where the toe kick will be installed.

   
   
3. 
   
   Step 3
   
   

   Arrange the end panels on the table so that the toe kick notches are away from each other. Measure up from the bottom and make a mark at 15¾ inches. Place the framing square on the mark and draw a line parallel to the one for the cleat. Place an "X" on the top side of the line. Repeat this for the other end panel. This is where the center shelf will be installed.

   
   

   Cabinet Assembly

   
   
4. 
   
   Step 1
   
   

   Apply wood glue to the area below the line for the bottom shelf. Place one of the 4 pieces of 4-by-19-by-¾-inch plywood on the glue and secure it with finish nails. Repeat this for the other end panel. Next, apply glue to one of the long edges of the two remaining pieces and secure it to the other piece to create an "L" shaped assembly. This will support the middle of the bottom shelf.

   
   
5. 
   
   Step 2
   
   

   Place the 2 pieces of 23-by-49½-by-¾-inch plywood on the table between the two end panels. These are the cabinet shelves. Stand one of the end panels on its back so the bottom shelf can be placed against the top of the cleat. Secure it through the end panel and into the shelf. Repeat this for the other end panel. Then apply glue to the widest side of the "L" shaped cleat and secure it to the bottom of the bottom shelf in the approximate center. Be certain it is flush with the back of the bottom shelf.

   
   
6. 
   
   Step 3
   
   

   Next, stand the middle shelf on its back edge and place it on the line from Step 3. Be certain it is on the side of the line with the "X". Secure it through the end panel with the finish nails. Repeat this for the other end panel.

   
   
7. 
   
   Step 4
   
   

   Install the 4-by-11-by-¾-inch plywood between and at the back edge of the shelves. Secure it with the finish nails through the top of the center shelf and the bottom of the bottom shelf. This will support the middle shelf.

   
   
8. 
   
   Step 5
   
   

   Apply glue to the front edges of the cleats and secure the 4-by-51¼-by-¾-inch plywood toe kick to them. Next, secure the 4-by-49½-by-¾-inch plywood at the top and back of the end panels. This serves as a back brace for the end panels and a nailing strip for the back of the cabinet.

   
   
9. 
   
   Step 6
   
   

   Turn the cabinet over so the face is facing down. Apply glue to the back edges of the shelves and the nailing strip. Set the 30-by-51-by-¼-inch plywood on the cabinet and secure with ½-finish nails.

   
   

   The Face Frame

   
   
10. 
    
    Step 1
    
    

    Place all of the 2-inch pieces of plywood on the table along with the 6-inch piece. Place the two 22¼-inch pieces between the 6-inch piece and one of the 2-inch pieces. Form a rectangle with them. The 22¼-inch pieces are the top and bottom rails.

    
    
11. 
    
    Step 2
    
    

    Place one of the 22¼-inch pieces at one end of one of the 32-inch pieces to form an "L". Secure them to each other with the corrugated fasteners. Repeat this on the other end of the 32-inch piece.

    
    
12. 
    
    Step 3
    
    

    Secure the assembly from the previous step to the 6-by-32-inch piece of plywood. This is the face frame.

    
    
13. 
    
    Step 4
    
    

    Determine which end of the cabinet is to fit into the corner of the wall, apply glue to the front edge and secure the remaining 2-by-32-inch piece of plywood on that end panel. Next, apply glue to the front edge of the other end panel and 27 inches of the front edge of the bottom shelf. Secure the face frame so that the 2-inch end piece is on the end panel. Allow it to hang over the end panel ¼-inch.

    
    
14. 
    
    Step 5
    
    

    Place the 6-by-23-by-¾-inch plywood between the back of the 6-inch piece of the face frame and the front of the back nailing strip. Center it with on the 6-inch end piece of the face frame and secure it through the front of the face frame and the back of the cabinet. Fill all nail holes with wood putty.

    
    

    The Door

    
    
15. 
    
    Step 1
    
    

    Place the 23¼-by-29-by-¾-inch plywood on the table along with the veneer strip. Cut two strips of the edging to 24 inches and two more at 30 inches. Place a strip to its matching edge and secure it to the edge with a hot iron. Repeat this for the opposite edges and let them cool so the adhesive will bond to the plywood.

    
    
16. 
    
    Step 2
    
    

    Fold the excess veneer over the corner edges of the door. Work the veneer back and forth until it breaks free. Repeat this for each corner of the door.

    
    
17. 
    
    Step 3
    
    

    Place the remaining strips on the other edges and secure them with a hot iron. Allow them to cool and then break off the excess. Sand the door with the electric sander. Use it to fold the veneer strips to the front and back of the door. Install the hinges on the door and then the door to the cabinet according to manufacturer's instructions.

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