How to Make Metal Cabinet Doors

Making custom metal cabinet doors can completely transform the look of your kitchen or bathroom. With some basic metalworking skills and the right tools, you can create durable, stylish cabinet doors to replace worn out or outdated ones. This comprehensive guide will walk you through the entire process of making metal cabinet doors, from choosing materials and designs to fabricating, finishing, and installing them. Follow these steps and you’ll have stunning new cabinet doors that add value and character to your home.

Choosing Materials for Metal Cabinet Doors

The first step is selecting the right type of metal to construct your cabinet doors. Here are some of the most popular options to consider:

Stainless Steel

Stainless steel is one of the most modern and sleek options for cabinet doors. It has a bright, shiny, and clean appearance that works well in contemporary kitchens. Stainless resists corrosion, rust, and stains while providing durability. Brushed finishes add visual interest and help hide fingerprints. Stainless is more expensive than other metals but provides a high-end look.

Aluminum

Aluminum is lightweight, resistant to rust, and available in a wide range of finishes like brushed, polished, or powder coated. It can look similar to stainless but is typically less expensive. Aluminum can dent more easily than steel but holds up well indoors. It provides a great balance of affordability, durability, and style.

Steel

Steel is the strongest and most durable metal option for cabinet doors. It provides dent, scratch, and corrosion resistance while allowing for custom shapes and designs. Steel doors can be painted any color or have a zinc, chrome, or brass plating applied. However, unprotected steel can rust over time, especially in kitchens.

Copper

Copper instantly adds visual warmth and a unique, handcrafted look. It will patina and change color naturally over time for more character. Copper is antimicrobial, meaning it kills bacteria on contact for hygienic cabinet doors. However, it is also one of the more expensive metals and requires diligent cleaning to prevent permanent tarnishing.

Metal Sheets vs Pre-Fab Doors

You can purchase pre-fabricated metal cabinet doors or construct your own custom doors using sheets of metal. Pre-fab doors simplify the process but limit your design options. Constructing your own allows you to fully customize shapes, sizes, and details. Most home DIYers go the custom route to achieve the exact look they want.

Selecting a Design for DIY Metal Cabinet Doors

After choosing your material, the fun part is picking a design! Take measurements of your existing cabinets and think about the look you want before deciding on door styles and hardware. Here are some popular design options:

Shaker Style

The classic shaker style with a square center panel and simple frame provides a clean, versatile look that works in almost any kitchen. Go for crisp white paint or stained wood for a traditional vibe.

Slab Door

A slab door offers a streamlined, modern aesthetic as a single flat panel without any frames. This minimal style is perfect for contemporary spaces and shows off metal finishes.

Glass Inserts

Adding a glass window gives your doors a unique touch while allowing you to showcase decorative dishware. Etched, frosted, or colored glass will provide privacy.

Curved Doors

For a more dramatic statement, curved doors make an eye-catching focal point. Bend metal sheets into gentle contours or dramatic swoops.

Farmhouse Style

Channel cottage charm with crossbuck doors featuring an X frame brace. Galvanized tin panels get an authentic rustic look.

Hardware

Don’t forget to pick the right handles, pulls, or knobs to complement your doors. Brushed nickel, black iron, and brass finishes work for various styles.

Matching Your Décor

Your cabinet door design should vibe with your overall kitchen or bathroom aesthetics. Keep them clean and simple for a modern space or add moulding and carved edges for traditional charm.

How to Build Metal Cabinet Doors

Once you’ve settled on a style, it’s time to start fabricating your doors. This requires some intermediate metalworking skills. Here is an overview of the key steps:

Create a Template

Take precise measurements of your cabinet fronts and draw out templates for each door on large sheets of paper. If doing multiple doors, make cardboard cutout templates to test sizing.

Cut Out Metal Panels

Use your templates to mark and cut the door shapes out of metal sheets with tools like jigsaws, plasma cutters, drill presses, or laser cutters. Be sure to leave 1/8” spacing for overlaps.

Cut and Assemble Frames

For framed doors like shakers, cut lengths of metal to assemble per your design using welds, screws, or rivets. Tip: Use butt joints instead of mitered joints for clean corners.

Attach Panels and Trim

Attach the center panels to the face frames with adhesive, welds, or rivets. Measure and cut any trim pieces needed to conceal edges.

Add Hardware

Attach hinges, pulls, handles, or knobs according to the manufacturer’s instructions. Ensure a secure, centered attachment.

Apply Finishing Touches

File down rough edges, fill gaps with epoxy filler, sand until smooth, and clean the doors thoroughly before finishing.

How to Finish Metal Cabinet Doors

Finish your custom metal doors to protect them and achieve your desired look:

Clean and Polish

For brushed steel or chrome doors, use metal polish and microfiber cloths to buff them to a clean sheen. Avoid cleaning perpendicular to the grain.

Oil Rubbed Bronze

This dark tinted, metallic finish works great on steel doors. Apply multiple coats of oil-based rubbed bronze paint for best results.

Lacquer or Enamel

For a glossy hue, spray or brush on clear lacquer or colored enamel paints. Allow proper drying time between coats.

Patina Solution

To naturally age new copper or bronze doors, apply a patina solution and let it sit to develop a greenish, aged look. Wipe and seal it after.

Wax

Wax applied with very fine steel wool will protect copper cabinet doors and enhance their lovely glow.

Paint

For stainless steel or aluminum that you want to paint, properly prep and prime the surface first so the paint adheres evenly.

Stain or Varnish

Stain, varnish, or oil will bring out the beautiful wood grain if you added a reclaimed wood panel insert.

Weathering

Some choose to artificially weather or oxidize metal doors for an authentic rustic, salvaged appearance. Use chemical solutions designed for this.

Installing Custom Metal Cabinet Doors

Once your doors are looking sharp, it’s time for the final step – installing them securely and properly:

• Carefully remove existing cabinet doors and door fronts along with any nails or screws.
• Hold each new metal door in place and mark hinge locations on cabinet frames.
• Drill pilot holes then attach hinges directly to cabinet frames with screws.
• Test opening and closing motion and make any hinge adjustments needed.
• Attach handles or knobs according to included hardware instructions.
• For glass panel doors, apply silicone caulk between glass and frame to prevent rattling and leaks.
• Make any final door alignment tweaks using shims if necessary for the best fit.
• Touch up paint spots or finishes as needed. Enjoy your stunning custom cabinet doors!

Frequently Asked Questions

Here are answers to some common questions about making your own metal cabinet doors:

What tools do I need to make metal cabinet doors?

You may need a jigsaw, table saw, drill press, angle grinder, welder, rivet gun, sander, metal shears, clamps, and safety equipment like gloves and eye protection. Hand tools like tin snips and hammers can also help shape and assemble doors.

What thickness of metal should I use?

16 to 20 gauge steel, aluminum, or stainless steel sheets typically provide sufficient durability for cabinet doors while still being easy to work with. Copper sheets are usually around 16 to 20 oz. in thickness.

Can I make metal doors look old and rusty?

Yes, you can artificially rust or patina metal to look aged and worn. Use chemical solutions and sanding techniques to achieve a vintage, weathered appearance. Or let copper and bronze doors age naturally.

Should I frame solid metal doors?

Framing provides reinforcement for larger doors but isn’t always necessary for small ones under 15” wide. Frameless, minimal styles work well with flat metal panels.

How do I attach handles to metal doors?

Most cabinet door handles use machine screw attachments. Drill pilot holes in the metal door, place the handle, and secure using Phillips head screws that come with the hardware.

Can I change the hardware on metal doors later on?

Most cabinet door hardware can be swapped out down the road if you want a new look. As long as you plug the old screw holes properly, different handles can easily be installed.

Achieve the Custom Look You Want

Upgrading kitchen or bathroom cabinets with new metal doors you construct provides limitless options for achieving the exact style you want while saving money and learning new skills. With the right materials, tools, and techniques, you can completely transform the look of your home with unique handcrafted doors. Just take it step-by-step to ensure precise sizing and quality fabrication. In the end, you’ll have durable metal cabinet doors that match your décor perfectly while adding personalized character wherever they’re installed.