George & Stephanie’s Kitchen Remodel

March 30, 2014 marks the day we started cutting wood for the kitchen remodeling project. Oak was selected for the wood to somewhat match all the moulding in the house. Stephanie directed the design phase by establishing storage requirements for her cookware. Additional cabinetry will be added to the kitchen area to increase the overall storage space. We hope you enjoy looking at the progress photos.

Old Cabinets

The existing cabinets had seen better days so it’s time to replace them.

Design

George enjoyed working with Sketchup to design the cabinets, taking into consideration Stephanie’s storage requirements.

Oak Stock

Oak left over from my kitchen remodel project provided material to start the project.

Miter Sawing

Taking measurements from Sketchup and a spreadsheet, a cutlist was prepared. Here George is sizing stock for panel glue-ups.

Sawing to Width

The stock was dimensioned to width at the cabinet saw.

Preparing the Edge

The edges were milled flat at the jointer then milled with a glue joint bit at the router table. This bit provides alignment and more surface area for a superior glue joint.

Panel Glue-up

The panels were glued using a jig designed for the task.

Sanding

After cutting the pieces to the proper width, they were drum sanded to a uniform thickness.

Dimensioned Lumber

Pieces cut to rough dimension waiting for additional milling and assembly.

Drilling Dowel Holes

The face frame incorporates dowel joinery. Here George is using the Dowelmax jig for precisely locating the holes on the rails and stiles.

Inserting Dowels

Gluing dowels in place for face frame assembly.

Cope Cut

Coping the door rail ends using a coping sled.

Panel Raising

Door panels were milled in about 5 passes. The back cutter was removed to mill the drawer faces.

Cutting Dovetails

Cutting dovetails using a Dovetail Wiz jig on the router table.

Sanding Door Panel

Sanding a door panel

Sanding panel end grain

A Fein Multimaster with sanding attachment makes quick work of sanding difficult end grain on a raised panel.

Gluing a raised panel door

Father teaching son the finer points of gluing up a raised panel door. To avoid confusion, the father is the guy with the gray hair.

Toe kick notches were cut using a jigsaw and temporary fence for alignment.

Toe kick notches were cut using a jigsaw with a temporary fence for alignment.

Sanding a face frame

The face frames were finished sanded to 220 grit.

Carcase glue up

All carcase members were glued together using tongue and groove joinery.

Gluing Carcase

Gluing the cabinet carcase parts to the face frame.

Door Hinges

Drilling the cup hole for European style door hinges.

Drilling Shelf Holes

The holes for the shelves were drilled using a jig.

tacking

Stephanie and Grace were a big help with sanding and tacking prior to staining. Here Stephanie is teaching Grace how to tack a piece of moulding.

Spray Finishing

George got an opportunity to apply the Urethane top coat using an Earlex HVLP sprayer.

Drying parts

Every square inch of garage space was utilized for staging and drying parts between coats of finish.

Transport

Finally! The cabinets were loaded up in the trailer and transported to George and Stephanie’s house. I get my garage and workshop back and Marilyn gets her craft area back to use on other projects.

Last Look

The old floor was removed and here is one last look at the old base cabinet before demolition.

Demolition

Stephanie had a blast using a Sawsall to cut through the old counter top.

More Work

You never know what you will find when an old kitchen cabinet is removed. Here we have water damage and a rotten sub-floor. The drywall and sub-floor must be repaired before proceeding with the installation.

Repair

George cut out the rotten sub-floor and found leaves and other debris under the floor. He also found bad joists that needed attention.

Repairs Completed

Everything was repaired and re-insulated in preparation for the new sub-floor and drywall.

Drywall

Installing new drywall.

Everything Patched Up

New drywall and sub-floor ready for sanding and painting.

Install Upper Cabinets

The upper cabinets were installed by finding the high spot on the floor plus 54″ using a self leveling laser. Since the base cabinets with counter top sit 36″ above floor level, the space to the base of the upper cabinets becomes a standard 18″.

Another Upper Cabinet

George attaching the doors to the upper refrigerator cabinet.

Partial Installation

Father and son in front of installed base and upper cabinets. The microwave oven gave us a little problem with door swing interference so we had to move the upper left cabinet over 3/8″ to correct the problem.

Project Complete

A photo of the completed project. George and Stephanie installed a ceramic tile floor by themselves to add the final touch to their kitchen remodel.

Breakfast Bar

After the cabinets were installed, George & Stephanie wanted a breakfast bar so the old man made this cabinet to finish the project. Unfortunately they were only able to enjoy their new kitchen for a short time because they sold their home in 2016. Goodbye cabinets!