How to Make Corrugated Metal Cabinets

Corrugated metal cabinets provide an affordable and durable storage solution for garages, workshops, and other utility spaces. Making your own corrugated metal cabinets allows you to customize the size, shape, and features to suit your needs. With some simple tools and materials, you can create sturdy, long-lasting cabinets for a fraction of the cost of buying pre-made ones.

Choosing Materials for Corrugated Metal Cabinets

The main component for corrugated metal cabinets is the corrugated sheet metal itself. This ribbed sheet metal comes in various thicknesses and sizes. Here are some tips for choosing the best metal sheets:

• Gauge – 26 to 29 gauge sheets provide the best balance of strength and affordability. Thicker 24 gauge can be used for larger cabinets.
• Galvanized Steel – Zinc coating resists rust and corrosion. Ideal for garage and workshops.
• Aluminum – More expensive but lightweight. Won’t rust. Good for outdoor use.
• Stainless Steel – Most expensive option but very durable indoor or outdoor use. Provides a modern look.

Other materials needed include:

• Framing – 1×2 inch lumber or square steel tubing for the cabinet frame.
• Fasteners – Self-tapping metal screws or rivets for assembling the metal sheets.
• Hinges – Heavy duty hinges designed for metal cabinets.
• Handles – Bar handles or recessed handles that attach securely to the metal.

Tools You’ll Need

You can build corrugated metal cabinets using common handyman tools:

• Safety gear – Gloves, eye protection, ear protection
• Saw – A jigsaw with metal cutting blades or an angle grinder with cut-off wheels
• Drill – Cordless drill with metal drill bits
• Rivet gun – Hand riveter or pneumatic rivet gun
• Screws – Self-tapping metal screws in various sizes
• Squares – Framing square and speed square
• Clamps – Spring clamps, C-clamps, vise grips
• Tin snips – For cutting and shaping metal sheets
• Tape measure – Preferably 25 foot minimum
• Pencil – Carpenter’s pencil or soapstone pencil
• File – Flat mill bastard file for smoothing cut edges
• Hammer – Ball peen hammer for riveting
• Gloves – Leather or heavy-duty work gloves
• Ear and Eye Protection – Safety glasses and earmuffs

These basic tools allow you to cut, shape, join, and finish corrugated metal cabinets. Having an organized workspace and safety equipment is also essential.

Designing Your Corrugated Metal Cabinets

Before building, you’ll want to decide on the size, style, and features of your corrugated metal cabinet set. Here are some design considerations:

• Storage needs – Determine what you intend to store so you can customize the shelves and compartments.
• Space available – Take measurements of the room or area to fit the cabinets.
• Cabinet height – Standard cabinet height is 34-1/2″, but you can adjust to fit your space.
• Cabinet width – Common widths are 12″, 18″, 24″, 30″, and 36″. Wider spans may need reinforcing.
• Cabinet depth – 12″ depth accommodates most storage needs. Increase to 16″-24″ for deep storage.
• Doors – Solid metal doors or mesh doors to allow airflow and visibility.
• Shelves – Fixed, adjustable, or removable shelves from metal or wood.
• Drawers – Optional drawers for smaller items. Requires cabinet framing.
• Work surfaces – Consider adding a metal countertop work surface.
• Locks – Keyed locks or latches to secure contents.

Creating a plan with dimensions allows you to calculate materials needed and build efficiently.

How to Make the Cabinet Frame

The frame provides the structure and shape of the corrugated metal cabinets. Here are the steps to assembling the frame:

Cut Lumber for Frame

1. Using a miter or circular saw, cut 2×2, 2×3, or 2×4 lumber to length according to your plans.
2. Cut pieces for the top, sides, bottom, middle supports, shelves, and face frame.

Assemble Frame

1. Lay out the pieces on a flat surface in their final positions.
2. Drill pilot holes for screws to prevent splitting the wood.
3. Use 3″ screws to assemble the top, sides, bottom, and middle support frames according to your design.
4. Attach cross-pieces for shelves at the desired heights. Use glue for extra strength.
5. Use brackets or gussets in corners for added stability if needed.
6. To create a face frame, cut 1×2 furring strips and attach them to the front perimeter.
7. Let the glue cure fully before proceeding if used.

The frame provides the structure to attach the metal skin and hardware too.

Installing the Corrugated Metal Sheets

With the cabinet frame built, you’re ready to add the corrugated metal sheeting:

Measure and Cut the Sheets

1. Measure between the edges of the frame for the side, top, and bottom panels. Leave 1/4″ extra.
2. Cut the corrugated sheets to size with tin snips or an angle grinder. Wear safety glasses and gloves.
3. File any rough edges smooth.

Attach the Sheets

1. Clamp the cut sheets in place over the frame.
2. Drill holes through the metal and frame 2″ apart.
3. If using screws, use self-tapping metal screws and drive them in with a drill.
4. For rivets, insert solid or pop rivets into the holes and use a rivet gun to affix them.
5. Work horizontally, fastening the center first and working outwards.
6. Attach metal corner trim or make 45 degree bend cuts to hide rough edges if desired.

Take care to keep the sheets square and level when fastening. The rivets or screws along the ridges provide maximum holding strength.

How to Install Cabinet Doors

You have several options for accessing the contents of your corrugated metal cabinet:

Solid Metal Doors

1. Cut doors 1/2″ smaller than the front frame opening.
2. Use 3 heavy-duty hinges for each door properly spaced along the frame side.
3. Mount the hinges into the door first, then into the frame.
4. Install a sturdy latch or lock hasp to keep closed securely.

Mesh/Perforated Metal Doors

1. Cut to size and fasten perforated sheet using screws or rivets like the panel sheeting.
2. Use edge trim to provide a finished, safe edge.
3. Optional lock hasp to secure contents.

Bi-fold Style Doors

1. Cut doors to width of cabinet and 50% of opening height.
2. Mount sliding door track to top and bottom frame front.
3. Attach door panels with piano hinges and mount in tracks.
4. Install floor catch to keep closed. Use lock if needed.

Adding Hardware and Accessories

Apply finishing touches and functionality with these hardware installation steps:

Shelves

1. Install pre-cut metal or wood shelving using shelf brackets mounted to sides.
2. For adjustable shelves, use shelf pins and standards.
3. Support deeper shelves with corrugated sheet metal screwed below for added strength.

Drawers

1. Build drawers out of wood with a plywood bottom for strength.
2. Mount drawer slides into frame cabinet sides.
3. Assemble drawers and mount into slides.

Handles

1. Measure and mark placement for handles horizontally centered on doors/drawers.
2. Pre-drill holes through outer panel layer only.
3. Use through-bolts or screw-down flanges to attach handles securely.

Locks

1. Use latch hasps or barred slide locks for wardrobe-style doors.
2. For solid doors, install flush mounted locks or surface deadbolts as desired.
3. Attach padlock rings to doors that need external locks.

With your preferred hardware installed, the metal cabinets are complete and ready to mount in place.

How to Install Your Corrugated Metal Cabinets

Follow these steps to hang your custom metal cabinets securely:

Worksite Preparation

• Clear the workspace and make sure the mounting surface is flat and level.
• Have shims and fasteners ready to achieve plumb and level cabinets.

Mounting Methods

Wall Cabinets

• Locate and mark stud locations to anchor to structural framing.
• Attach 2×4 cleats to the wall studs at the top and bottom.
• Lift and fasten the cabinets into the cleats through the back panels.

Floor Cabinets

• Set cabinets in position and shim as needed to level.
• Attach through bottom and back into floor and wall studs.
• Secure adjoining cabinets together through sides.
• Anchor taller units to wall for stability if not positioned under wall cabinets.

Mobile Cabinets

• Bolt caster wheels to the bottom of cabinets.
• For garage use, add leveling feet to compensate for uneven floors.

Utility Room Mount

• Hang wall cabinets first following cleat method.
• Set base units on floor, anchor to wall, and attach to wall cabinets.

Now fill your corrugated metal cabinets to enjoy maximal storage for any space!

Tips for Customizing Your Corrugated Metal Cabinets

Part of the appeal of building your own corrugated metal cabinets is the ability to create a custom look and function. Here are some ways to customize:

• Add colorful metal trim for accent colors against the black, gray, or galvanized metal.
• Include pegboard panels for hanging tools and gear.
• Mount plastic bin racks for see-through storage.
• Mix cabinet sizes like full height pantry size and half-height tool caddies.
• Incorporate a built-in workbench or utility table.
• Install specialty racks and holsters for sports equipment, gardening supplies, or workshop tools.
• Use chalkboard panels for labeling contents or decorating.
• Include locking jewelry drawers or secure rifle and ammo storage.
• Build a metal enclosure with access doors for hiding valves and meters.

With sturdy corrugated metal and quality hardware, you can design your own personalized storage solutions.

Maintenance Tips for Corrugated Metal Cabinets

Once installed, corrugated metal cabinets are quite durable with minimal maintenance needs. Here are some tips for keeping them looking and functioning like new:

• Wipe down occasionally with a damp cloth using mild detergent or degreaser to remove dirt and residues.
• Dry thoroughly with a soft cloth to prevent water spots.
• Open doors and vents periodically to allow ventilation and drying if humidity is an issue.
• Inspect rivets or screws annually and tighten any that are loosening up.
• Apply touch up paint as needed for any scratches or chips to prevent rust.
• Occasionally apply paste wax to the surface for added protection and shine.
• Re-align doors or drawers that settle out of square over time. Adjust hinges and slides as needed.
• Use quality locks, latches, and handles for longer service life with less repairs.
• Repaint interior of cabinets every 2-3 years to refresh the look.

Your well-built corrugated metal cabinets should last for many years with simple care when needed. Enjoy the benefits of durable, custom storage!

Frequently Asked Questions About Making Corrugated Metal Cabinets

What tools do I need to make metal cabinets?

You’ll need basic tools like a jigsaw, drill, rivet gun, clamps, screwdrivers, and safety gear like gloves and eye protection. Useful extras include a circular saw, miter saw, tin snips, grinder, file, welder, and rivet tool.

Where can I buy corrugated metal sheets for cabinets?

Check your local home improvement stores, metal supply shops, or online sources. Prices range from $15-50 per 4×8 sheet depending on material, gauge, and finish.

What size should I make corrugated metal cabinets?

Common widths are 12, 18, 24, 30 and 36 inches. Heights often match kitchen cabinet dimensions of 30 – 36 inches. Depth can range from 12 – 24 inches deep depending on contents.

How thick should the metal be?

26-29 gauge provides good durability at a moderate cost. For heavy duty use, upgrade to 24 gauge or higher. Aluminum can be thinner than steel, around 20-24 gauge.

What kind of paint should I use?

For raw steel, use a quality metal primer followed by industrial enamel spray paint. For galvanized metal, use a bonding primer or etch the surface before painting.

How are perforated metal cabinet doors made?

Perforated sheets can be cut to size and fastened into the cabinet frame like solid panels. Alternately, you can make a frame and attach mesh screen material.

Can I build metal cabinets outdoors?

Yes, corrugated metal cabinets are weather resistant and work well for covered outdoor areas like porches, patios, and workshops. Use galvanized or stainless steel for maximum rust resistance.

Conclusion

Building your own corrugated metal cabinets allows you to inexpensively create durable storage customized to your specific needs. Follow the steps outlined to construct the cabinet box, add doors and hardware, then mount your cabinets securely. With the right materials, tools, and know-how, you can build cabinetry that will last for years while saving considerable cost over buying pre-fab units. Get started on designing your ideal metal cabinets and make the most of the versatile storage space they provide.