How to Make Corrugated Metal Cabinet Doors

Making custom corrugated metal cabinet doors can add an industrial flair to your kitchen or workspace. With some simple tools and materials, you can create durable and stylish doors that will transform the look of your cabinets. Here is a step-by-step guide to making corrugated metal cabinet doors.

Introduction

Corrugated metal sheets give a ribbed texture that provides both aesthetic appeal and strength. Used for everything from roofing to siding, corrugated metal offers versatility for DIY projects. Cabinet doors made from corrugated metal have a modern, industrial vibe perfect for contemporary, urban, or farmhouse decors.

Custom metal doors allow you to match the color to your existing cabinets or purposefully contrast them. You can also cut the doors to fit cabinets of any size. Constructing the doors yourself provides an opportunity for creativity and customization at a fraction of the cost of purchasing metal doors.

Benefits of Corrugated Metal Cabinet Doors

• Durable – Metal stands up well to daily wear and tear. Corrugated sheets are rigid and sturdy.
• Stylish – The ribbed metal texture gives an eye-catching, sleek industrial look.
• Customizable – Metal doors can be cut to size and painted any color.
• Affordable – Building your own doors costs less than buying premade ones.
• Easy to clean – Metal wipes clean easily.

With some simple DIY skills, you can build corrugated cabinet doors suitable for kitchens, garages, basements, laundry rooms, and more.

What You’ll Need

• Corrugated metal sheets
• Hinges
• Handles or knobs
• Self-tapping metal screws
• Drill with metal-cutting bits
• Jigsaw with metal-cutting blades
• Measuring tape
• Safety gear – gloves, eyewear, etc.

Optional items:

• Paint/primer if coating the metal
• Brad nailer to assemble door

Step 1: Measure Cabinet Openings

Take measurements of each cabinet space the new doors will fit. You’ll need the height and width. Measure precisely, accounting for any trim or edging. Cutting the doors a little small is better than having them too large.

Make sketches of each door’s dimensions to use as a cutting guide. For double doors, remember to divide the width in half per door. Add about 1/4″ extra wiggle room to the height and width.

Step 2: Cut Metal Sheets to Size

Using your measurements, mark and cut the corrugated metal sheets to size for each door. Use aviation snips for simple straight cuts or a jigsaw with a metal blade for curved cuts. Wear leather gloves as the metal edges are very sharp.

Cut slowly and smoothly to minimize rough edges. File or sand any sharp burrs if needed.

Step 3: Drill Holes

Drill holes in the metal for:

• Handle/knob – Trace a template and drill center holes. For extra support, use thin sheet metal screws secured from the interior side.
• Hinges – Mark hinge positions and drill holes to match the hinge template. Deburr holes if needed.
• Fastening to cabinet – Drill holes every few inches around the perimeter of the backside.

Go slowly with steady pressure when drilling metal. Use a center punch to keep the drill bit from wandering. Lubricating the bit helps, too.

Step 4: Prime and Paint (Optional)

For a painted look, apply a metal primer followed by your choice of paint color. Allow proper drying time between coats.

Be sure to use spray paints formulated for metal. Enamel provides a durable finish.

Paint the door exterior, edges, and interior surface for full coverage. Add multiple light coats for best results. Consider a bar pull or other handle rather than knobs for a smooth flat finish.

Step 5: Install Hinges

Attach hinges to the door following the manufacturer’s instructions. Have a helper hold the door in place while installing hinges to ensure proper alignment.

Use self-tapping metal screws (not wood screws) to secure the hinges. Drill pilot holes with a smaller bit first if screws won’t thread easily into the metal.

Step 6: Hang Doors and Install Hardware

With hinges attached, lift the door up to the cabinet opening. Have someone support the door on the interior side.

Align hinge plates flush to cabinet frame. Position hinge leaves parallel to each other. Mark hinge locations on the cabinet.

Take door off and drill pilot holes in cabinet front at the marked spots. Then screw hinges into place.

Install door handles or knobs centered at a comfortable height. Add any additional bracing, trim, or closures along outer edges if needed.

Step 7: Seal and Finish Edges

For sharp exposed metal edges, fold over a hem or attach metal edge trim. Use silicone sealant along seams to prevent moisture entry.

Wipe excess sealant away quickly before drying. Remove paint drips or overspray if needed. Allow paint or sealant to cure fully before regular use of the doors.

Tips for Making Quality Doors

• Use at least 26 gauge metal or heavier for durability.
• Cut carefully and deburr all edges to prevent cuts and scratches.
• Make doors 1/8″ smaller than the cabinet opening for easy operation.
• Pre-drill holes for hinges and hardware for clean installation.
• Apply primer and paint properly for greater longevity.
• Seal edges carefully to prevent moisture damage.
• Ensure door aligns flush within the cabinet frame.

Advantages of Custom Metal Doors

Installing handcrafted corrugated metal cabinet doors provides numerous benefits:

• Cost savings – Making your own doors is much cheaper than buying ready-made ones.
• Custom sizes – Get a perfect fit by tailoring doors precisely to each cabinet.
• Creative control – Choose unique colors and designs not found on store-bought doors.
• Strong and secure – Metal doors are more durable against damage from pets, kids, and heavy use.

With some simple tools and materials, you can build and mount custom corrugated metal doors. They will give any room an eye-catching industrial chic look.

Frequently Asked Questions

What type of metal works best for cabinet doors?

Galvanized steel or aluminum at least 26 gauge in thickness provide durability. Avoid thinner or flimsy metals prone to denting. Go for a ribbed corrugated panel for added strength.

What tools do I need to make metal doors?

A jigsaw with metal cutting blades, variable speed drill and bits, hole saw, files, tape measure, carpenter square, level, clamps, safety goggles, and work gloves.

How do I cut the metal neatly?

Use a jigsaw with a fine tooth metal blade or aviation snips. Cut slowly and file any rough edges. Mark cut lines with masking tape.

What’s the easiest way to hang metal doors?

Pre-drilled pilot holes allow self-tapping screws to thread cleanly into the metal. Use hinges designed for metal doors along with the correct screws.

How do I get a smooth painted finish on metal?

Proper preparation is key. Clean the surface well, apply metal primer, then spray on thin even coats of enamel spray paint allowing proper drying between layers.

Conclusion

Installing DIY corrugated metal cabinet doors provides a custom look at a fraction of the cost of buying factory-made metal doors. With some simple tools and materials, you can create durable, stylish doors tailored to your specific cabinet dimensions. Pay attention to precise measurements, proper prep and painting, and secure hardware installation. Then enjoy the handsome, modern appeal corrugated metal doors add to any room.