How to Mount Sheet Metal on Cabinet

Mounting sheet metal on a cabinet can give it a sleek, modern look while also providing extra protection and durability. With the right tools and techniques, installing sheet metal cladding on a cabinet is a relatively straightforward DIY project. This guide will walk you through the complete process of preparing, cutting, and mounting sheet metal to cabinet surfaces using best practices.

Benefits of Using Sheet Metal for Cabinet Cladding

Sheet metal offers several advantages as a cabinet facing material:

• Aesthetics – Sheet metal provides a smooth, uniform look and comes in a variety of metal finishes like stainless steel, copper, brushed nickel etc. This allows you to match the cladding to your cabinet hardware and decor.
• Durability – Metal surfaces are inherently scratch, dent and peel resistant. This makes sheet metal ideal for high-wear areas like cabinet doors and faces.
• Customization – Sheet metal can be cut to size and formed into customized profiles and patterns. This allows for more unique designs compared to wood or laminate.
• Weather resistance – Metal does not warp or degrade easily when exposed to moisture. Sheet metal cladding helps protect cabinet boxes in bathrooms, laundry rooms and other damp environments.
• Easy to clean – Sheet metal cabinet fronts can simply be wiped down unlike porous materials like wood. The smooth surface does not trap dirt or grime.
• Fire resistance – Metal is non-combustible and slow to heat, making it safer than wood or laminates around cooking areas.

So if you are looking to upgrade your existing cabinets on a budget, sheet metal cladding provides an inexpensive yet transformative solution. The installation process does take some DIY skill but yields a durable and stylish result.

How to Prepare the Cabinet for Installation

Proper prep work is crucial for getting clean, long-lasting results from your sheet metal cabinet cladding project. Here are the key steps to take before starting installation:

Ensure Cabinet Boxes are Plumb and Square

• Verify all cabinet cases are level and plumb. Use a spirit level to check that sides, top and bottom are at precise 90 degree angles.
• Look for any warping or twisting, and use shims as needed to square the boxes. Proper alignment now means less hassle mounting panels.

Choose Appropriate Grade Sheet Metal

• For cabinet cladding, a thickness between 18 and 22 gauge is ideal. Thinner metal is prone to dents while thicker is hard to cut and manipulate.
• Opt for galvanized steel or aluminum if painting. For a metal finish look, stainless steel, brushed nickel or copper sheets work well.
• Select metal with smooth, defect-free surfaces. Avoid materials with blemishes, pits or scratches which become visible after installation.

Clean Surfaces Thoroughly

• Use a degreaser to remove any existing oils, dirt or residue from the cabinet face frames and door fronts.
• Sand glossy laminates lightly with 120-150 grit sandpaper to improve adhesion. Clean sanded surfaces fully with a dry cloth.

Add Support Strips Where Needed

• Glue wooden strips along the edges and openings of the cabinet face using construction adhesive.
• This provides extra support areas for attaching sheet metal panels, preventing warping.

With prep work complete, you can move on to measuring and cutting the sheet metal to size.

How to Measure and Cut Sheet Metal for Cabinets

Carefully measured cuts ensure your metal panels fit your cabinet dimensions perfectly with uniform gaps for a quality finish. Follow these steps:

Measure Panel Dimensions

• Use a steel tape measure to accurately measure the height and width of cabinet doors and face frame areas to be covered.
• For doors, measure the precise dimensions of the center panel excluding outer frames.
• Add an extra 1/4″ – 1/2″ to the height and width of each measured dimension. This provides a margin of error for trimming.

Transfer Measurements to Sheet Metal

• Lay the sheet metal on a flat work surface and mark cut lines using a permanent marker and steel ruler.
• Use a square to ensure the marked lines are at precise 90 degree angles.
• Double check your measurements match the cabinet dimensions before cutting.

Cut Out Panels with Shears

• Use straight aviation snips to cut along the marked lines. Cut 2-3 passes along each line slowly applying pressure.
• Wear gloves to protect hands and grip metal firmly while cutting to prevent vibration and jagged edges.
• Finish cuts by firmly squeezing snips along each line to the edge to separate panels. Remove any sharp burrs with a metal file.
• For holes, mark size and use a punch tool followed by snips to cut the opening. Deburr the edges smoothly.

Bend Metal Where Required

• To create returns, notches or end tabs, use a sheet metal brake to bend the cut panels precisely.
• For simpler 90 degree bends, use a sturdy vise and mallet instead. Protect the finish when hammering.
• Make relief cuts at corners and curves to allow metal to bend cleanly before forming dies.

With accurately fabricated sheet metal pieces, you are ready to move on to installation.

How to Mount and Secure Sheet Metal to Cabinets

Follow these steps to attach the sheet metal panels to your cabinet frames and doors for a flawless finish:

Position Panels and Mark Attachment Points

• Place the precut sheet metal pieces in position on the cabinet and align evenly along top, sides and corners.
• Use a pencil to mark the stud locations and perimeter of the cabinet on the backside of each panel.
• Also mark the location of any knockouts, openings or vents to be transferred onto the metal.

Drill Holes for Screws

• Based on your marks, drill holes slightly larger than your fastener screws using a step drill bit.
• Space holes every 8-12 inches around the perimeter and edges evenly. Make holes along any interior vertical braces as well.
• Drilling holes before attachment allows precise positioning and prevents the metal from warping.

Attach Metal Panels with Screws

• Place panels back on the cabinet aligning the drilled holes to the marks on the frame and box.
• Fasten into place from the center outwards using self-tapping sheet metal screws.
• On door fronts, use short screws to avoid protruding through the backside.

Seal and Conceal Screw Heads

• For a clean look, sink screw heads slightly below the surface with a center punch.
• Fill any gaps around screws with automotive body filler, sand smooth and repaint if needed to conceal.
• Alternatively, use snap caps or colour matched plugs to obscure visible screw heads.
• Caulk perimeter edges with clear silicone sealant for a watertight seal.

With your sheet metal panels securely mounted, the cabinet cladding is complete! Now you can enjoy your modern metal-wrapped cabinets that are built to last.

FAQs About Mounting Sheet Metal on Cabinets

Some commonly asked questions about installing sheet metal cladding on cabinets include:

What tools do I need to install sheet metal on cabinets?

You will need basic metalworking tools like aviation snips, vise grips, drill, screws, and protective gloves and eyewear. Use tin snips for straight cuts, pneumatic shears for curves, and a sheet metal brake for clean bends and folds.

What thickness of sheet metal should be used?

18 to 22 gauge steel or aluminum sheets work well for cabinet cladding. Under 18 gauge is hard to cut while over 22 gauge dents easily. Stainless steel should be at least 20 gauge thick.

How are sheet metal panels attached to the cabinet?

Self-tapping sheet metal screws are used to attach the panels securely to the underlying cabinet. Pre-drill slightly oversized holes in the sheet metal before mounting it. Use even spacing and adequate screws for a sturdy result.

What are some tips for cutting sheet metal cleanly?

Use new sharp aviation snips, cut 2-3 passes slowly applying firm pressure, support metal near the cut, and cut away from your body. Finishing edges with vise grip pliers also helps achieve clean cuts.

How can I get custom profiles and bends in sheet metal?

Use a sheet metal brake to make straight 90° bends and folds. For custom curves and shapes, use a sheet metal slip roll or metal shear. Make small relief cuts at corners before bending to prevent cracking and deforming.

Should I insulate between the cabinet and sheet metal?

Thin insulation foam or rubber pads can help reduce vibration noise and improve heat/cooling insulation if needed. Adhere sheets or strips using permanent bonding caulk compatible with both materials.

Conclusion

Installing sheet metal cladding on worn or outdated cabinets is an impactful upgrade that looks great and adds lasting durability. With some DIY metalworking skills and attention to detail, the process of measuring, cutting, and mounting sheet metal panels is quite straightforward. The result is a modern, custom look and rugged performance that withstands busy households. Just be sure to prep cabinets properly, allow margin for error when cutting, and attach metal firmly using screws suited for sheet metal. With this guide’s step-by-step instructions, you can tackle sheet metal cabinet cladding confidently and enjoy the benefits for years to come.