How to Build Corrugated Metal Cabinet Doors
Building your own corrugated metal cabinet doors can be a fun and rewarding DIY project. With the right materials and techniques, you can create durable, stylish doors that will give your cabinets an industrial look and feel. Here is a comprehensive guide on how to build corrugated metal cabinet doors from start to finish.
Introduction
Corrugated metal sheets make excellent material for cabinet doors and panels. The corrugated design gives the metal extra rigidity and strength while also providing visual interest. Galvanized steel is the most popular choice, but aluminum and copper sheets can also be used.
Corrugated metal cabinet doors are perfect for contemporary, industrial, or farmhouse style kitchens. The ridged metal pairs nicely with exposed beams, concrete counters, and stainless steel appliances. Corrugated doors also have sound dampening properties that can help reduce clangs and bangs from pots, pans and dishes inside the cabinets.
Benefits of Corrugated Metal Cabinet Doors
- Durable and dent resistant. The corrugated ridges make metal doors very sturdy.
- Stylish industrial look. Corrugated metal brings texture and character.
- Sound dampening. Reduces noise from items banging around inside cabinets.
- Customizable. You can cut metal sheets to any size and shape.
- Affordable option. Corrugated metal sheets are budget friendly.
- Easy to clean. Just wipe down with soapy water.
Supplies Needed
Building corrugated metal doors will require a few essential supplies:
- Corrugated metal sheets
- Cabinet door hinges
- Handle and latch
- Self-tapping metal screws
- Electric drill and drill bits
- Metal snips
- Measuring tape
- Tin snips for cutting and shaping metal
- Rubber mallet
- Safety glasses and gloves
Step 1: Measure Cabinet Openings
The first step is to carefully measure the width and height of each cabinet opening that requires a new door. It is critical to get very precise measurements so the custom metal doors will fit correctly.
Be sure to measure from the exact points where the cabinet door will attach at the top and sides. Write down all measurements for reference. Having the exact width, height, and depth values for each cabinet door you need to build will be essential.
Step 2: Cut Corrugated Metal to Size
With your measurements in hand, you can now cut the corrugated metal sheets down to the proper dimensions for each cabinet door using metal snips.
Be sure to double check all measurements before making any cuts. Put on safety glasses and gloves for protection. Carefully cut along your marked lines using metal snips designed for thick sheets. Take it slow to get a clean edge.
Cut the metal slightly larger than the cabinet opening. It is easier to trim off any excess than to add material. Cut each door panel to the required size according to your recorded measurements.
Step 3: File and Smooth Cut Metal Edges
Once the metal sheets are cut down to size, use a metal file to smooth any rough or sharp edges along the cut seams. This helps prevent cuts from the thin unfinished metal.
Carefully file down each edge, being cautious of sharp burrs. Rubbing gently with an abrasive sanding sponge can also help soften cut edges. Filing and sanding will create a nice finished edge.
Step 4: Mark and Drill Holes for Cabinet Door Hinges
With the door panels cut, it’s time to mark and drill holes to attach the cabinet door hinges. Refer to the hinge installation guide for hole placement. Most hinges require 2 holes per side.
Measure and mark hole locations on the inside of the corrugated metal door panel. Use a center punch to make a divot before drilling to prevent the drill from wandering. Clamp panels to a steady surface before drilling.
Go slowly with the drill, using a bit slightly smaller than the screw size. The ridged door can flex so take it easy and keep panels secure. Drill out both sets of hinge holes on each door panel.
Step 5: Attach Hinges to Door Panels
With the hinge holes drilled, position hinges on the backside of each metal door panel. Use metal self-tapping screws that are slightly longer than the door’s thickness.
Make sure hinges are oriented correctly before driving screws into place with a drill/driver. Attach both sides of the hinges securely. Test the doors by opening and closing to ensure proper hinge function before installing.
Step 6: Hang Doors and Attach Hardware
You’re almost done! Now it’s time to hang the corrugated metal doors on the cabinets with the attached hinges. Lift into place and adjust as needed for proper alignment and swing.
Attach any additional hardware like pulls, latches, or self-closing hinges. Make any minor adjustments to ensure doors open and close smoothly with no binding or rubbing. Add weatherstripping as needed to cushion and reduce noise.
Step 7: Seal and Finish Edges
For an extra clean look, you can apply edge banding trim to conceal any rough seams or holes along the door sides. Flexible adhesive-backed metal edge banding attached with an iron creates a seamless edge.
Alternatively, a bead of clear silicone caulk run along raw edges can seal any gaps and smooth the finish. Wipe away any drips for a neat appearance. Allow caulk to fully cure before closing doors.
Tips and Considerations
- Utilize metal duct tape when cutting metal to prevent sharp burrs
- Use a rubber mallet to flatten any warps or bends in cut metal sheets
- File edges in direction of grain texture to avoid catch
- Pre-drill holes for hardware to prevent tearing metal
- Add sound dampening strips for reduced noise and vibration
- Countersink screw heads and fill for a flat finish
- Avoid placing doors near heat sources to prevent warping
With the right preparation and techniques, DIY corrugated metal doors can add custom style to any kitchen or cabinet at a fraction of the cost of traditional doors. Just take care to measure twice and cut once for a perfect fit. Safety glasses and gloves are a must when working with thin sheet metal. With patience and the proper tools, you’ll achieve durable, eye catching metal doors for your cabinets.
Frequently Asked Questions
What type of metal works best for corrugated cabinet doors?
Galvanized steel is the most common choice for its strength, affordability and corrosion resistance. Aluminum and copper can provide visual interest but are not as rigid and prone to dents. Stainless steel provides ultimate durability but is expensive.
What thickness metal should I use?
24 to 26 gauge galvanized steel offers a good balance of durability and workability for cabinet doors. Heavier gauges are harder to cut and drill. Lighter metal can lack rigidity.
Can I paint or stain corrugated metal doors?
Absolutely. Priming and painting metal doors is recommended to prevent corrosion and add color. Use high adhesion primer and metal enamel paint. Stain provides minimal protection.
How are corrugated metal doors attached?
Sturdy door hinges designed for metal are attached using self-tapping screws. Follow the template in hinge hardware pack for proper placement. Pre-drill holes to prevent tearing thin metal.
How do I cut corrugated metal sheets?
Use aviator snips, electric shears or an angle grinder with a cut-off wheel designed for cutting thin metal. Mark cut lines and clamp sheet metal securely before cutting. Wear eye protection.
Do corrugated doors reduce noise?
The ridged design helps dissipate vibration and sound. Using sound dampening strips around the perimeter further reduces noise from metal doors bouncing against the cabinet frame.
Conclusion
Installing DIY corrugated metal doors is an achievable project for any home handyperson. With careful measurements, some simple tools, and safety precautions, you can create custom metal doors that lend an appealing textured look to your cabinets. Visually interesting and durable, corrugated doors provide a budget-friendly way to refresh dated cabinets. Just follow the steps outlined above and take your time for best results. Enjoy the satisfaction of replacing worn out doors with new galvanized steel doors you fabricated yourself. Your kitchen will have an upgraded modern style with the addition of handsome corrugated metal cabinet doors.
