How to Build Metal Cabinets

Introduction

Metal cabinets are a great way to add durable, long-lasting storage to any home, office, or workshop. With the right materials and techniques, you can build customized metal cabinets that perfectly suit your space and organizational needs. This comprehensive guide will walk you through the entire process of building metal cabinets, from planning and design to construction and installation. Follow along to learn the fundamentals of metalworking and cabinetry so you can create your own quality cabinets.

Planning Your Metal Cabinets

Before you start building, take time to plan out your metal cabinet project. This planning will ensure the finished product meets your expectations and storage requirements.

Determine the Use

First, decide how you will use the finished cabinets. Consider what you need to store, how much space you need, and any specialty organizational features that would be useful. Metal cabinets are incredibly versatile – they can store tools, office supplies, kitchen items, bathroom essentials, and more. Your intended use will inform decisions like size, shelves, and drawers.

Choose a Location

Determine where you want to install the metal cabinets. They are often built as freestanding units, but can also be mounted on a garage wall or anchored into a workshop. Measure the available space to find out what size cabinets will fit. Also consider existing electrical, plumbing, and other elements that may impact the cabinet layout.

Design and Dimensions

Sketch designs showing the cabinet dimensions, features, and configuration. Standard kitchen cabinet sizes like 30 or 36 inches wide work well, but you can fully customize the proportions. Design organizational elements like shelves, drawers, and doors tailored for what you will store inside. Measure carefully to optimize usable storage space.

Materials and Hardware

Metal cabinets are typically constructed from galvanized steel, stainless steel, or aluminum. Galvanized steel is affordable and offers durability in garages, sheds, and workshops. Stainless steel provides a sleek look and withstands moisture for bathrooms or outdoor kitchens. Aluminum is lightweight yet strong. Determine what materials you want to work with based on available tools, skills, and budget. You will also need hinges, handles, shelf brackets, and drawer slides appropriately sized for the cabinets.

Constructing the Metal Cabinet Boxes

With a plan in place, you can start constructing the individual metal cabinet boxes that will form the core structure. This step involves cutting and shaping sheet metal into panels using welding or mechanical fasteners to join them. Safety first – wear eye protection, gloves, and other protective gear when metalworking.

Cut the Metal Panels

Measure and mark out the required panel dimensions on sheet metal per your plans. You will need material for the sides, top, bottom, back, shelves, and any doors. Cut the pieces carefully with aviation snips, an angle grinder, or a plasma cutter if you have access to one. Deburr all cut edges.

Form the Sides and Back

Bend the side and back panels to form right angles using a sheet metal brake, bending jig, or vise grips clamped along the bend line. Bend each panel incrementally tapping with a mallet until the desired 90 degree angle is achieved. This creates the box frame.

Join the Pieces

Attach the assembled side/back pieces to the top, bottom, and any shelf panels using welds, pop rivets, or self-tapping metal screws. Clamp pieces together ensuring corners are square. Space fasteners every 4-6 inches for solid connections. Grind welds smooth when completed.

Add Structural Stiffeners

Welding angle irons horizontally along the inside cabinet backs will stiffen the assembly and prevent racking. This helps square the cabinet boxes and enable doors/drawers to function properly. The angle iron size depends on cabinet width – 1″ x 1″ up to 2″ x 2″ on larger cabinets.

Doors, Drawers, and Interior Fittings

With the main cabinet box built, you can now add functional elements like doors, drawers, and interior organizational hardware.

Hanging Doors

Measure and cut doors from additional sheet metal, allowing 1/8″ clearance on all sides. Attach hinges designed for metal using the provided fasteners.TEST metal cabinets initially to ensure proper alignment before final attachment. Adjust as needed for smooth operation.

Installing Drawers

Fabricate drawers or order ready-to-assemble drawer boxes in sizes to match your cabinet openings. Mount full extension drawer slides to the cabinet interior following the manufacturer instructions. The slides allow full access to the drawer space when pulled open.

Shelves and Dividers

Cut shelving from wood or sheet metal. Notch shelves around vertical stiffeners. Insert into the cabinet box resting on shelf clips attached at desired heights. You can also install partition walls or dividers secured with rivets or welds to create smaller storage compartments.

Drawer Organizers

Consider adding dividers, trays, and other aftermarket organizers inside drawers to neatly arrange contents. Look for modular plastic or metal drawer organizers that can be adjusted to fit your needs.

Finishing Metal Cabinets

The final step is applying a finish to protect the metal while giving your cabinets the desired look.

Clean Surfaces

Thoroughly clean cabinet surfaces removing any oil, rust, mill scale, or dirt. For raw steel, sand using 80 grit sandpaper followed by 120 grit. Wipe clean with a solvent like acetone.

Apply Primer

Spray all cabinet surfaces with an etching metal primer formulated for galvanized steel, stainless steel, or aluminum depending on your base material. Allow primer to fully dry per manufacturer instructions. Fill any dings or dents and sand smooth.

Topcoat Paint or Stain

Apply two finish coats in your choice of durable spray enamel paint or metal stain. Allow proper drying time between coats. For indoor cabinets, a semigloss or gloss paint provides a smooth finish that’s easy to clean. Use exterior grade finishes for any cabinets placed outdoors.

Attach Hardware

Once fully dry, mount handles, pulls, or knobs on doors and drawers. Stick-on rubber bumpers on doors help cushion contact and prevent metal-on-metal banging. Your custom metal cabinets are now ready to be loaded up and used!

FAQs about Building Metal Cabinets

How thick should the sheet metal be?

16 or 18 gauge sheet steel provides good durability for most cabinets. Go up to 14 gauge for larger sizes or 12 gauge if you need very heavy duty.

What tools do I need?

Basic tools like a drill, grinder, mallet, clamps, and measuring instruments are essential. A sheet metal brake simplifies bending panels. Welding equipment, snips, shears, or a plasma cutter allow you to customize dimensions.

How much weight can metal cabinets hold?

It depends on the design, but a typical 30″ base cabinet can hold 100-200 lbs on the bottom shelf. Weight capacity decreases for upper shelves. Sturdy wall mounted cabinets can support up to 50 lbs per linear foot.

Should I bolt cabinets together?

Bolting with angles brackets or shelving standards creates a more integrated installation and distributes weight across multiple studs/anchors. This prevents sagging or pulling away from the wall over time.

Can I build outdoor metal cabinets?

Yes, use weather resistant materials like aluminum or stainless steel. Apply marine grade polyurethane or epoxy paint. Include drainage holes and keep stored contents protected from moisture. Use extra anchors when mounting outdoors.

Conclusion

Building your own metal cabinets allows full customization to suit your storage needs and space. Follow the steps and techniques outlined to construct durable, long-lasting cabinets from sheet metal. With good planning and some metalworking skills, you can create cabinetry that perfectly fits your garage, workspace, kitchen, or any area needing organization. The finished cabinets will provide you with years of robust storage and great satisfaction from a job well done.