How to Fix Old Metal Cabinets

Old metal cabinets can develop a variety of issues over time that make them less functional and attractive. With some time and effort, it is possible to restore metal cabinets to a more usable condition. This article provides detailed instructions on common fixes and restoration techniques for old metal kitchen cabinets, bathroom cabinets, garage cabinets and more.

Assessing the Cabinet Condition

Before beginning repairs, thoroughly examine the cabinet inside and out to identify all problem areas. Look for:

• Rust
• Corrosion
• Dents and dings
• Peeling paint/finish
• Warping
• Door/drawer alignment issues
• Loose or missing hardware
• Shelves in need of repair/replacement

Make notes on each cabinet’s current state so you can prioritize which ones need repairs first. Focus initial efforts on cabinets with extensive rust, corrosion or alignment issues as those problems will only worsen over time if not addressed.

Removing Rust and Corrosion

Rust and corrosion lead to unsightly marks and can eventually cause metal to weaken and fail. It’s crucial to remove oxidation and inhibit future rust formation.

Supplies Needed

• Safety glasses & gloves
• Respirator mask
• Paint scraper
• Wire brush
• Sandpaper (80-120 grit)
• Rust removal solvent
• Rust converting primer
• Clean rags

Instructions

1. Protect yourself: Wear safety glasses, gloves and a respirator mask to avoid inhaling particulates. Rust removal chemicals can irritate eyes and skin.
2. Remove loose rust: Use a paint scraper to peel off any loose, flaking rust. Avoid scraping too aggressively so you don’t remove more good metal than necessary.
3. Scrub with a wire brush: Gently scrub remaining rust spots with a wire brush to lift oxidation from the metal surface. Focus on affected areas rather than scrubbing the entire cabinet.
4. Sand away stubborn rust: For areas where wire brushing fails to remove rust, use 80-120 grit sandpaper to sand down to bare metal. Sand in the direction of the grain.
5. Clean with solvent: Wipe sanded areas with solvent designed for rust removal to dissolve and lift remaining oxidation. Let solvent sit for 5+ minutes before wiping away.
6. Apply rust converting primer: Once rust is removed, apply a rust converting primer like Rust-Oleum to chemically convert any traces of rust into an inert material and prevent future corrosion.
7. Allow to fully cure: Before adding your final paint/finish, allow converting primer to cure for the time specified on the product label. Proper curing is essential for rust prevention.

With the rust fully removed and converted, you can proceed with refinishing the cabinets.

Repairing Dents and Dings

Over years of use, old metal cabinets accumulate plenty of dents, dings and damage. While some minor imperfections add character, deep dents should be remedied to restore a smooth, uniform appearance.

Supplies Needed

• Rubber mallet
• Block of wood
• Putty knife
• Auto body filler putty
• Sandpaper

Instructions

1. Knock out deep dents: For dents you can access the back side of, place a block of wood on the inside of the dent and gently tap with a rubber mallet to push the metal back into shape.
2. Fill with putty: For remaining dents and dings, use an auto body filler putty, applying putty over the depression and smoothing with a putty knife. Let putty fully cure.
3. Sand smooth: Once cured, sand the putty smooth and flush with the surrounding cabinet surface using graduated grit sandpaper.
4. Prime and paint: Apply primer to the putty, then repaint the cabinet when finishing to hide any putty repairs. With careful sanding and painting, repairs become nearly invisible.

Correcting Warped Cabinets and Doors

Humidity, age and improper installation can cause cabinet boxes and doors to warp out of shape. Thankfully, warping can be reversed without replacing cabinets.

For Warped Doors:

• Place the concave side down on a flat work surface.
• Wet several towels and place them on top of the warped section.
• Weigh the towels down with books, clamps or other heavy objects.
• Check after 20-30 minutes. Repeat wetting towels and adding weight until door flattens.

For Warped Cabinet Boxes:

• Empty the cabinet and remove doors/drawers.
• Use helpers or clamps to force the box back into proper shape.
• Place shims or blocks in gaps behind the warped area and attach with adhesive or screws.
• Add additional screws through the cabinet back into shims to hold it flat as it dries.

It can take hours or days for a warped cabinet box to stabilize in the corrected position. Keep checking it and re-shimming as needed while the wood acclimates.

Adjusting Doors and Drawers

Over time, cabinet doors and drawers can become misaligned, preventing them from closing properly or creating uneven gaps.

Supplies Needed

• Screwdriver
• Shim stock
• Wood putty

Instructions

1. Diagnose alignment issues: Note where doors or drawers are too high/low so you know which areas need adjustment.
2. Loosen hardware: Partially back out hinge or drawer slide screws to allow movement for adjustments.
3. Realign doors: Insert shims above or below hinges to raise/lower doors until even gaps are achieved.
4. Realign drawers: Loosen drawer slide screws and adjust slide placement as needed to center drawers.
5. Retighten hardware: Once realigned, retighten all hardware. Test opening/closing. Repeat adjustments if needed.
6. Fill gaps: Use wood putty to fill any remaining gaps for a seamless look. Sand smooth once dry.

Reglazing Chipped Porcelain

Porcelain drawer, cabinet and sink surfaces often chip with heavy use. Luckily, porcelain reglazing products allow you to repair chips and refresh the finish.

Supplies Needed

• Porcelain repair kit
• Putty knife
• Sandpaper
• Tack cloth

Instructions

1. Clean surface: Remove all residue from the porcelain and surrounding area with soap and water. Let dry fully.
2. Sand chipped area: Lightly sand the damaged porcelain and feather the edges. This helps the reglazing compound bond.
3. Wipe away dust: Use a tack cloth to remove any dust left from sanding. Dust will hinder adhesion.
4. Mix and apply reglazing compound: Prepare compound as directed. Press into chip with a putty knife, overfilling slightly.
5. Smooth edges: Once applied, wipe away any excess and smooth edges for a flush finish. Allow to fully cure.
6. Blend repaired area: Use fine grit sandpaper to blend the edges of the repair into the original finish. Buff to an even sheen.

With careful application and blending, the reglazed area will be nearly invisible. Repeat repairs as needed on all damaged porcelain.

Reinforcing Shelves

Shelves that sag over time can often be reinforced instead of fully replaced. This saves time and money.

Supplies Needed

• Brackets or corbels
• Screws
• Wood glue
• Sandpaper

Instructions

1. Remove shelf: Take the shelf out to access its underside. Empty the shelf first.
2. Sand underside: Lightly sand the shelf bottom to remove gloss/residue so glue adheres.
3. Apply reinforcing glue: Run a bead of wood glue down the shelf length.
4. Attach supports: Space brackets or corbels evenly under shelf. Secure with screws into underside.
5. Allow to cure: Let adhesive fully cure before reloading shelf. Test weight capacity before restocking fully.

Adding more contact points through shelf supports prevents future sagging. This approach can add decades more life to old shelves.

Refinishing the Cabinet Exterior

Refinishing cabinets through painting, staining, or refacing can make worn cabinets look like new again. Proper prep is crucial for good results.

Instructions

1. Clean surfaces: Use TSP cleaner and scrub pads to remove grease and grime from cabinets. Rinse thoroughly.
2. Fill holes/imperfections: Use wood filler to patch holes from old hardware. Sand smooth when dry.
3. Sandcabinets: Lightly sand to degloss and roughen the finish. Dust thoroughly after sanding.
4. Prime: Apply primer suited for metal to block stains/tannins and ensure paint adhesion.
5. Paint/stain: For painting, use a high quality enamel cabinet paint. For staining, use penetrating stains meant for metal.
6. Add protection: After painting/staining, apply a clear polyurethane for added protection and durability.

With thorough prep and careful application of new finishes, you can give worn cabinets an updated facelift. Properly refinished cabinets look factory fresh.

Removing Odors from Inside Cabinets

Unpleasant lingering odors inside cabinets can make stored items smell bad. Musty cabinet smells usually stem from mildew growth.

Instructions

1. Empty cabinets: Remove all stored items so you can access all cabinet interior surfaces.
2. Clean with baking soda solution: Mix baking soda and water into a paste. Scrub solution onto all interior surfaces.
3. Rinse thoroughly: Use clean water on a sponge or rag to rinse away baking soda residue from inside cabinets.
4. Allow cabinets to dry: Keep cabinet doors open and run a fan to accelerate drying after cleaning.
5. Place charcoal bags inside: Activated charcoal absorbs lingering odors. Place mesh bags of charcoal on cabinet shelves.
6. Check regularly: Refresh charcoal bags every 1-2 months until odors dissipate fully. Avoid reintroducing smelly items.

Thorough cleaning and deodorizing removes musty smells at the source. Maintaining a dry cabinet interior prevents future mildew growth.

Repairing or Replacing Hinges and Hardware

Cabinet hinges and hardware handles inevitable wear over decades of use. Repairing or replacing hardware revives functionality and aesthetics.

Supplies Needed

• Screwdriver
• Hinge pins
• Metal epoxy (for hinge repair)
• New hinges and handles

Instructions

1. Check hinge pin tightness: Using a screwdriver, check that all hinge pins are still tightly screwed in place. Tighten any loose hinge screws.
2. Test hinge function: Open and close cabinet doors and observe hinge function. Note any squeaking, sticking or poor door movement.
3. Attempt hinge repairs: If possible, remove problematic hinge leaves and use metal epoxy to fill stripped screw holes. Reattach hinge.
4. Replace non-repairable hinges: For non-functioning hinges that cannot be fixed through screwtightening or epoxy, fully replace old unit with new hinge.
5. Replace handles: For modernizing cabinets, consider replacing outdated hardware knobs and handles with new ones instead of refinishing old hardware.

With repaired or new hardware installed, cabinets operate smoothly once again.

Keeping Cabinets Organized Inside

A disorganized and cluttered interior can make cabinets frustrating to use. Use these tips to maximize storage function:

• Install organizers like divided turntables, drawer inserts and shelf risers to optimize vertical space.
• Clearly label shelves and drawers to make locating items easy.
• Designate shelves or drawers for certain categories of items.
• Store items you use most often in easiest-to-reach areas.
• Get rid of unused items taking up space so cabinets don’t become overstuffed.
• Wipe spills immediately and avoid storing liquids on shelves long-term to prevent leaks.

Maintaining organization ensures cabinets remain clutter-free and sanitary over the years.

HVAC Considerations to Avoid Future Damage

Proper temperature and humidity control can prevent many common issues with metal cabinets long-term.

• Keep indoor relative humidity between 30-50% to inhibit corrosion and warping. Use dehumidifiers as needed.
• Avoid situating cabinets next to heat and cooling vents where temperature fluctuations are most extreme.
• Insulate garage cabinets from wide temperature swings by covering or moving them away from poorly sealed exterior walls.
• Install spacers between cabinets and walls in bathrooms and kitchens to allow moisture to escape instead of being trapped.

Following HVAC best practices reduces moisture damage and dimensional changes that compromise cabinets over time.

When to Call a Professional

While many cabinet repairs can be completed successfully DIY, certain issues are best left to skilled cabinet restoration professionals:

• Extensive rust-through that structurally compromises the cabinet
• Large dents that prevent doors/drawers from opening properly
• Severely warped cabinet boxes that fail to hold their shape once reshimed
• Hinge mortises and door notches that are misaligned or prevent proper door closing
• Major holes, gaps or missing pieces too large to patch with common wood fillers

Cabinetmakers have specialized tools and expertise needed for significant restoration work. Their services are worthwhile for complex repairs.

Safety Tips for Working on Cabinets

When taking on any cabinet repairs yourself, follow these basic safety measures:

• Use eye and ear protection when sawing, sanding, chiseling or drilling metal.
• Wear a mask when working with chemicals, paints, solvents or creating dust.
• Wear heavy work gloves when handling rusted metal to avoid cuts.
• Work in a well ventilated area and follow product label instructions.
• Use sharp blades, bits and sandpaper to avoid binding and kickbacks.
• Make sure cabinets are securely supported on a level surface before attempting repairs.
• Get help moving extremely heavy cabinets, and use proper lifting techniques.

Exercising caution keeps you safe while reviving old metal cabinets. With some diligent restoration work, they can serve your home for many more years looking and functioning like new. Proper care and maintenance will extend their beauty and durability even longer.