How to Make Cabinet Doors Using Corrugated Metal
Making cabinet doors out of corrugated metal can add an industrial, rustic, or vintage look to your kitchen or bathroom. With just a few basic tools and materials, you can create durable and stylish custom doors that will transform the look of your cabinets.
Introduction
Corrugated metal sheets provide an affordable and easy way to make custom cabinet doors. The rippled texture of the corrugated metal gives the doors visual interest and dimension. Corrugated metal comes in various colors like galvanized steel, copper, brass, and more so you can choose a look that fits your style.
Making corrugated metal doors yourself allows you to customize the size and shape. And unlike wood doors, metal doors won’t warp or crack over time. With just a few simple steps, you can add beautiful new doors that will upgrade your space.
Benefits of Using Corrugated Metal for Cabinet Doors
- Durable – Corrugated metal is extremely sturdy and built to last. The doors will maintain their integrity for years to come.
- Rustic aesthetic – The rippled metal material has an industrial, vintage look. It adds texture and charm.
- Customizable – You can cut the metal to any size and shape to fit your cabinets.
- Affordable – Corrugated metal sheets are budget-friendly, especially compared to custom wood doors.
- Easy to clean – Metal wipes clean easily.
- Fire resistant – Metal won’t burn or enable flames to spread.
What You’ll Need
- Corrugated metal sheets
- Tin snips
- Drill with various drill bits
- Self-tapping metal screws
- Hinges
- Handle or knob
- Eye and ear protection
- Work gloves
- Measuring tape
- Pencil or marker
- Sandpaper
- Paint/stain (optional)
Steps to Make the Doors
1. Measure the Cabinet Openings
- Carefully measure the width and height of each cabinet opening that needs a new door. Record the measurements.
- Add 1/4 inch to the height and width for adjustment room.
- Cut the corrugated metal 1/2 inch larger than the opening on all sides to allow room for folding over edges.
2. Cut the Metal to Size
- Using tin snips, cut the corrugated metal sheets down to the proper measured size for each door. Wear gloves and eye protection.
- Cut slowly and make straight smooth cuts for best results.
- If desired, use sandpaper to smooth cut edges.
3. Mark and Drill Holes
- Lay the cut metal sheets on a flat surface and mark where screw holes need to be drilled.
- On the inside of the door, mark where hinge holes will go. Make sure they line up precisely with the hinge positions on the cabinet frame.
- Drill out all marked holes slightly larger than the screws.
4. Attach Hinges and Handle
- Screw hinges into pre-drilled holes on the inside of the metal door sheets.
- Attach hinges to align perfectly with those on the cabinet frame.
- Screw handle/knob into place on the outside of door.
5. Fold and Attach Door
- Carefully fold over the edges of the cut metal sheet about 1/4 inch on all sides.
- Working on one door at a time, fold the metal over itself as tightly as possible for clean edges.
- Attach folded door to aligned cabinet hinges using self-tapping metal screws. The folded edges allow for a finished look.
- Repeat the process for all doors.
6. Add Paint or Stain (Optional)
- If desired, paint or stain the doors to match your cabinets or for extra decorative flair.
- Lightly sand first for best paint adhesion. Clean and dry fully.
- Apply two coats of latex paint or stain, allowing full drying time between coats.
And that’s it! You now have beautiful custom corrugated metal doors that upgrade your cabinets affordably. Proper measuring, cutting, drilling, and folding are key to getting doors that fit right and look sharp. Take your time with each step. Custom metal doors add durability, texture, and charm to any kitchen or bath.
Tips for Installing Corrugated Metal Doors
- Allow a 1/4 inch gap between doors and frames for adjustment.
- Pre-drill holes slightly larger than screws to prevent cracking metal.
- Use pan-head self-tapping metal screws.
- Fold over edges tightly for clean finished look.
- Ensure hinges align perfectly to prevent doors from sagging.
- Use tin snips for smooth cuts; sand any rough edges.
- Apply painter’s tape around hinges before painting for clean lines.
- Consider adding insulation inside doors to reduce noise.
- Wipe away metal shavings frequently when cutting to prevent cuts.
FAQs About Making Corrugated Metal Doors
What gauge (thickness) of corrugated metal should I use?
- 26 to 28 gauge metal provides sufficient thickness and durability for cabinet doors. Anything thinner may dent too easily. Heavier gauges are too thick for folding over edges.
What’s the best way to get clean cuts in the metal?
- Investing in good quality tin snips and taking it slow will produce the cleanest cuts. Support the metal as you cut and don’t try to cut too much at once.
How do I get crisp folded edges?
- Use a block of wood or rubber mallet to hammer over the folded metal tightly and evenly. Apply pressure close to the bend for sharp 90 degree angles.
What type of drill bit should be used?
- Standard twist drill bits work well for thinner gauges of metal. For thicker metal, use tin snips to cut holes or a step drill bit.
How do I get rid of scratches and dents in the metal?
- To smooth out small dents, use a rubber mallet and hammer from the inside. For shallow scratches, rub with fine grit sandpaper.
Should I insulate the doors?
- If noise reduction is a priority, you can cut insulation to size and glue it inside the doors using construction adhesive before folding over edges.
Conclusion
Installing custom corrugated metal doors provides an easy upgrade that instantly modernizes standard cabinets. By taking accurate measurements and using simple tools, you can create durable doors unique to your space. Add interest and rustic flair to your kitchen or bathroom with on-trend metal doors you make yourself. Just be sure to work slowly and carefully for best results. With a little time and effort, you can dramatically update the look of your cabinets without breaking the bank.
