How to Make a Corrugated Metal Cabinet Door
Making a corrugated metal cabinet door can be a fun DIY project that allows you to add a unique, custom look to your kitchen or bathroom cabinets. With some simple tools and materials, you can create a durable and stylish corrugated door that will transform the look of your cabinets.
Introduction
Corrugated metal sheets make for excellent cabinet doors due to their ridged pattern that provides both visual interest and strength. The wavy design gives the metal rigidity while allowing it to be bent into shape. Corrugated metal is available in various metals like steel, aluminum, copper, and more, so you can choose a material that fits your budget and desired look. With the right techniques, you can craft a custom corrugated door yourself.
Things You’ll Need
Before starting this project, assemble the necessary tools and materials:
- Corrugated metal sheets in your preferred metal type and gauge
- Tin snips for cutting the metal
- Drill with metal drill bits
- Rivets and rivet gun
- Hinges and handle/pull of your choice
- Eye and ear protection -safety first!
Make sure you have corrugated sheets large enough to cover the size of your cabinet door with extra for handling. Also have ready reinforcement pieces, like wood or additional metal, for rigidity.
Step 1 – Measure the Cabinet Opening
First, remove the existing cabinet door and measure the opening carefully. Mark down the height and width. This will determine what size corrugated metal sheets you need to purchase. Add 1-2 inches to the measurements to give you extra room for error.
Be sure to measure the depth of the cabinet as well, from front to back, so you know the sizing for any reinforcement woods pieces you may add later.
Step 2 – Cut the Metal to Size
With your corrugated sheets, use tin snips to cut the metal to your measured size. Clamp a straight wood guide to the sheet if needed, to get straight cuts.
Be sure to wear safety glasses and gloves when cutting the metal. Take your time for clean, even cuts.
Tip: Cut the metal a bit larger than your measurements to give some leeway for mistakes. You can always trim it down smaller later.
Step 3 – Drill Holes for Hinges
Lay your cut corrugated sheet on a flat surface and mark where you want the cabinet hinges to go. Use a measuring square to plot hinge placements accurately.
Using a metal drill bit, drill holes for mounting the hinges – typically 3 holes per hinge. Go slow and steady with the drilling to avoid messing up the holes.
Step 4 – Attach Hinges and Pull
With holes drilled, attach the cabinet hinges to the corrugated metal using the provided screws. Follow the hinge instructions for proper installation.
For the handle or pull, mark the placement and drill holes as needed. Attach the pull securely with provided hardware.
Step 5 – Add Reinforcement Pieces
For stability and rigidity, corrugated doors need some type of reinforcement. This is commonly 3/4″ plywood cut slightly smaller than the door size.
Rivet or screw the plywood pieces onto the backside of the metal. Having wood along the top, bottom, and one side is sufficient. The wood will prevent the door from flexing and rattling.
Step 6 – Hang the Door
With hinges and reinforcements attached, you can now hang the corrugated door on the cabinet!
Use a helper for this part if needed. Have one person hold the door in place while the other screws the hinges into the cabinet frame.
Make any final adjustments. The door should open smoothly without touching the cabinet sides.
Step 7 – Seal and Finish the Metal
For protection and aesthetics, apply sealant and finishing paint to the door.
Wipe it down first with mineral spirits to clean. Apply 2-3 thin coats of metal sealant, allowing it to fully dry between coats.
Finish with 1-2 coats of spray paint in a color of your choosing. Let the paint cure fully – around 5-7 days.
Tips for Success
- Use heavier gauge metal for a more durable door. 20 gauge steel or 0.032″ aluminum recommended.
- File any sharp metal edges to prevent cutting yourself.
- Add weatherstripping tape for a tighter seal and sound dampening.
- Use metal-specific spray paint for best adhesion and corrosion resistance.
- Consider adding small woven metal mesh behind corrugations for a more decorative look.
FAQs
What tools do I need to make a corrugated metal door?
You’ll need basic tools like a drill, rivet gun, tin snips, measuring tape, safety gear, clamps, straightedge, and screwdrivers. A jigsaw is also handy for cutting any wood reinforcement pieces.
What thickness of corrugated metal should I use?
26 gauge is suitable for most residential cabinet doors, but go with 24 gauge or thicker if you need extra durability. The lower the gauge number, the thicker the metal.
How do I get clean cuts in the corrugated metal?
Use tin snips designed for cutting curves and waves. Go slowly and brace the metal firmly while cutting. A wood guide clamped on as a straightedge also helps.
What’s the best way to hang the metal door?
Sturdy cabinet hinges specifically made for metal doors are best. Use at least 2 hinges and make sure they are installed precisely.
Should I paint or seal the corrugated metal?
Sealing with a metal sealant helps protect against corrosion and moisture damage. Painting the door gives you design options, just be sure to use exterior metal paint.
How can I dampen noise from a rattling metal door?
Adding plywood reinforcement helps. You can also stick small foam pads onto the door interior or install weatherstripping tape around the door edges.
Conclusion
Installing a DIY corrugated metal door on your cabinets can give them an industrial, sleek look with the right techniques. While it takes some effort, the unique ridged pattern and metallic sheen are worth it for many homeowners. With the right preparation and tools, you can create durable, stylish corrugated doors tailored exactly to your space.
