I'll continue to post as I make that progress!
Herb - the door for that cabinet will be made from the material I cut out since there is some T-trim and door trim that takes up a fair amount of space between the two. It's nice that I can resuse the material since it is laminated and color matched.
Speaking of which, I bought some laminate that is a very close match and modified one of the end panels of the cabinet pictured above. It used to have a door built into it but since I am making a new door for easier access I don't need two. I disassembled the cabinet and used the original panel not only for a template to route the door opening but also to route the outline of the replacement panel. Then I followed the simple steps of rough cutting the laminate, preparing the pieces with Contact cement, adhering them and then flush edge trimming. It was quite easy and just required some preparation to get all my material together.
I'm jumping backwards a bit here from my original post but these are the images of my modification in chronological order from the start of my cabinet mod.
I sketched out my intended cuts on the face of the cabinet. My goal was to align the top and the bottom with an existing door on this face so that things look clean to the eye. You will see that I have an inside line that is for the door outline and an outside line for the cabinet opening. Its a generous 5/16" between the two so I figured I would go ahead and use a jigsaw to make the cut and ensure I used a reverse tooth blade so that if I did chip laminate it would be on a non cosmetic surface ie. the inside of the cabinet. I also taped the inside of the cut line with blue painters tape and it seemed to work well to prevent chipping. A nice new sharp 10 TPI Bosch blade worked very well. As you can see, I relieved the corner radii by drilling a number of 5/32 holes to allow the jigsaw to maneuver more easily through these sections. I also drilled a few holes very tightly together which allowed me to get a start for my jigsaw blade.
Like I already mentioned, I wanted to eliminate the door in the side panel of this cabinet since it was no longer needed. So I used the old panel as a template and made myself a new one sans door. It was then time to laminate and trim and I'm quite happy with the results so far, its a perfect match. I still need to make a rabbet cut on this panel, add a few dado slots for shelves and then reassemble.
After I finish this modification to this cabinet I am going to tackle the kitchen cabinet which will be made from scratch. I decided to go this route because I felt the modification would let me get my hands dirty and help me build some experience with the tools and processes, especially the order of fabrication and how to leverage the tools I own.
Last edited by Topher; 06-24-2015 at 12:37 PM.