I've been building face frame cabinets with melamine interiors. I'd like to hear how cabinetmakers are building melamine carcasses. I have been using full length bottoms and tops with walls in between. I use a few biscuits for alignment and screw together with coarse drywall screws. While this gives good results, it doesn't seem like the most efficient method. I've been reading about confirmats in the posts but haven't tried them. Do they hold that much better than drywall screws? How are the parts held in alignment while they are inserted? Any other methods being used? I don't have the equipment for dowels.
From contributor C:
Biscuit joinery is good, but parts need to be set longer than doweling for the biscuit to swell. If you don't have a construction doweler, this is a good way to go.
Upper and lower box ends run through (shelves in between) with a 1/4x1/4 dado 3/4" in from back edge for back panel with two 3 3/4 nailers added to back after assembly with pocket screws.
All parts are cut with melamine blades 1/8" oversize and run through a router table using a straight bit cutter that takes off 1/16" each pass for a chip-free edge for banding, etc.
Wood parts are stained and finished prior to assembly. Toe bases are attached to the cabinet underside during construction with cleats, and if you want a finish end that runs to the floor, a veneer can be applied and stained and finished after assembly. We also use hot melt glue around the back panel after squaring.
Screws work well and omit the glue-up time, but you will have to use veneer on finish ends. We use the screw system on laminated boxes.
We have been thinking about the possibilities of using the pocket screws for assembly with veneering on finish ends and bottom of uppers but don't know if the screws' diameter would be strong enough to withstand handling till the job is installed.
In reality, one should get a vertical/horizontal boring machine that does line and construction boring and use a box clamp to assemble and square the boxes.
Jon Elvrum, forum technical advisor
Jon Elvrum, forum technical advisor
I agree - get rid of the drywall screws and get particleboard screws. The kind with the cutting ridges under the head so you don't need your countersink bit are awesome. I did use Quickscrews, but my supplier changed brands and I can't recall what these are now. Also, square drive screws work much better - they stay straight on the driver bit.
You would have two dedicated routers set up on a router table. One for the single pass dovetail dado on the inside end pane that stops 3/8" from the front (stop dado) and the other for the two passes for each side of the shelf which make the tongue. You would need to make this cut (the tongue) a little smaller to allow for glue in the joint and easier assembly. After the parts are milled, you would glue your dovetail dado and slide the shelf in, assemble the back - cleats, etc. - square the box and hot melt the edge of the box and back. The key is to make the match just right and be careful of humidity that could make the exposed parts (especially the tongue) swell and be difficult to assemble. Actually, the box should be assembled as soon as it is milled and if spraying finish parts, first the tongue and dado should be closed or protected so there will not be buildup of finishes or any way that the parts would swell.
Of course, the construction boring and dowels are by far the best, but there are lots of ways to assemble frameless boxes and what works for one will not for others.
Biscuits, dowels, confirmats for face frame cabinet carcasses? That is a complete waste of profits and adds no significant strength to the cabinet - it isn't going anywhere.
Face frame cabinets hang by the nailer strip, which is placed under the top - every part of the carcass captured on at least two if not three of its planes by nails or staples, using the sheer strength of the nails (you remember, like houses used to be built in better times). More than enough strength here in earthquake CA. Glue the frames on a squared case, sand, detail and hang the doors and drawers and deliver the friggin' thing and get paid.
Cut parts that are the right size, assemble them in an orderly, common sense fashion and move on.
Costs to produce frameless systems are less to build and by utilizing the 32mm system, holes can be a breeze. Lumber used in the making of the frame can be utilized in the doors, which is one less step in constructing, assembling and finishing.
Comment from contributor B:
One of the contributors denounces drywall screws in favor of wood screws. There is nothing wrong with drywall screws if the holes are properly drilled, but it is difficult to get them perfectly flush, even if the hole is bevelled. This is because they are actually "bugle heads" as opposed to bevelled. Also, the holding power of wood screws has long been discredited because of the tapered threads, especially in MDF. Best, in my opinion, is sheet metal screws, with a true bevelled head. They have greatest strength and best holding power.