An Inside Look at Cabinets Manufactured run the gamut on price, materials and craftsmanship

BY SCOTT GIBSON

t the giant KraftMaid cabinet fac- into three grades: stock, semicustom and tory just outside Cleveland, work- custom. The labels don't mean as much as A ers stand by with glue guns and they once did, but they are still a good start- pneumatic nailers as parts for a complete set ing point. of kitchen cabinets approach on a conveyor. Stock cabinets are at the low end of the Drawers, face frames, prefinished panels, market. Available in limited styles and fin- shelves and moldings arrive from all corners ishes and with fewer options, stock cabinets of the million--foot plant. Although are built in standard sizes in increments of the customer who ordered this kitchen may 3 in. in width. They are manufactured and have taken months to plan its every detail, then stockpiled, without regard to who will KraftMaid assemblers will put it together in buy them. Semicustom cabinets are built to 15 minutes. Cabinets are shipped about a order, also on a 3-in. grid, and offer more week after the order has arrived. choices when it comes to styles, accessories Did you think your new kitchen cabinets and finishes. Materials may be of higher would be hand-built by fussy artisans? Guess quality. Custom cabinets, such as those from again. Cabinets are a $6 billion industry, and Rutt, are built to fit the available floor space they pour off assembly lines like hubcaps or exactly with just about any option the cus- lawn chairs. If that prospect unsettles you, tomer is willing to pay for. They are the most consider a smaller company, one like Rutt expensive of all. Custom of Goodville, Pennsylva- And then there are the small shops, the lo- nia. Here, panels are matched for color cal cabinetmakers found in virtually every and figure, one board at a time. A specialist corner of the country. Working on one job at is standing by to custom-blend a color. a time, these shops turn out cabinets de- The catch? Rutt charges more than twice as signed for just one client. Detailing, con- much, and you can count on waiting 40 or 50 struction and selection may range days to get your order. from ordinary to exquisite. Yet these cabinets KraftMaid and Rutt are only two among are not manufactured in the same sense as hundreds of cabinet manufacturers. Yet they factory-built, mass-produced goods. Exam- tion. Although the process is wide-ranging help to illustrate the many choices buyers ples of that more individual work can be and rigorous (roughly half of those seeking will face before plunking down thousands of found throughout this issue. certification for the first time will flunk), it's dollars for a new kitchen. Any cabinet is a sum of its parts, and the not useful for comparing individual compo- choices can seem overwhelmingly compli- nents such as drawers, and cabinet Manufactured kitchens fall into cated. Assessing quality is not always easy. boxes. And makers of high-end cabinetry three general categories Many manufacturers submit their cabinets may skip the test altogether. To help make sense of what's available, the to the Manufacturers As- Whatever the cabinet industry's tests show, industry has traditionally divided cabinets sociation for voluntary testing and certifica- it pays to buy cabinets that are carefully built from good-quality materials and hardware. Prices vary as widely as quality. Bottom-of- rials and accessories. A custom-manufac- To me, that means avoiding cabinets made the-line stock cabinets for a kitchen of tured kitchen can approach $20,000. from paper-coated panels or ones with thin roughly 120 sq. ft. are available for less than The following pages look in detail at four shelves that bend under pressure. Drawers $2,500, not including countertops and in- manufactured base cabinets that are typical should open smoothly, without wobbling. A stallation. According to estimates provided of what's on the market. More expensive of- finish should be silky to the touch, without by both KraftMaid and Merillat, one of the ten means more quality and a longer life. But any visible sanding marks. In short, buyers country's largest cabinet manufacturers, a getting the best value also should include a should seek cabinets that look and feel as if better-quality kitchen might range from just careful look at the many differences in con- they are solidly made. over $5,000 to $12,800, depending on mate- struction, hardware, finish and materials. CABINET BOXES: YOUR KITCHEN'S FOUNDATION

A salesman may call the cabinet French solid wood is attached to the front of a a frameless cabinet, overlay doors and provincial, Shaker or Arts and Crafts, but or particleboard box. Face drawer fronts hide the cabinet box. Of- from a construction standpoint, manu- frames create square door and drawer ten made from melamine, which is par- factured cabinets are one of two types: openings while adding strength to the ticleboard covered by a thin layer of traditional face frame or frameless. In a cabinet and helping to keep it square plastic laminate, these cabinet boxes face-frame cabi- during construction, shipping and instal- are usually held together with net, a rigid lation. Depending on the type of hinge and glue. frame made used, some or all of the frame is visible The days of solid-wood construction of -in. when doors and drawers are installed. In are long gone, mainly because panel

$125 STOCK FACE-FRAME CABINET MADE WITH LIGHTER MATERIALS This cabinet, made by Kitchen Kompact of Jeffersonville, Indiana, uses a traditional face frame to reinforce the front of the carcase. In this price range, some materials are likely to be relatively thin with a simulated wood-grain finish. 6 Carcase: Materials include sides of -in. wood-veneer particleboard, and a back of -in. vinyl-covered . The cabinet floor is -in. vinyl-covered hardboard that flexes under a load. Corner blocks that reinforce the cabinet are stapled in place, but not all of the staples hit their target 7 Shelf: Not adjustable and only in. thick, the 11-in. wide shelf is made of vinyl-covered particleboard. 8 Drawer: Sides are -in. faced in a wood-grain vinyl with a solid drawer front of red . 9 Door: A wood-veneer panel is set in a frame of solid oak. Hinges cannot be adjusted.

$115 FRAMELESS MELAMINE IS INEXPENSIVE, EASY TO CLEAN Frameless cabinets, such as this melamine base unit from LesCare Kitchens of Waterbury, Connecticut, use a full overlay door and drawer front that span the width of the carcase. Upgrading the door and drawer front to a more durable high-pressure laminate raises the price of this cabinet to $180. 1, 2 Carcase: Cabinet sides are -in. melamine-faced particleboard with a -in. back and a -in. floor. Parts are assembled with glued joints and are reinforced with full-width stretchers. 3 Shelf: Held in place by adjustable plastic clips, the -in. melamine shelf is 12 in. deep, about half the depth of the cabinet itself. 4 Drawer: Sides of -in. melamine are doweled and glued together with a -in. bottom and a thermofoil drawer front (medium-density fiberboard wrapped in plastic). 5 Door: A full-overlay thermofoil door is hung on adjustable hinges that can be removed without any , making it easy to pop off the door for a thorough cleaning. products such as plywood, particle- sure laminate used on countertops. Box- choice for kitchen cabinets. It's tough board or medium-density fiberboard es of veneer-core plywood, lighter and and durable. In cheaper cabinets, the make a stronger, more stable cabinet at stronger than particleboard, also are top coat may look glossy and rough, a lower cost. Upper and lower cabinet available but often cost more. Whether with some sanding marks still visible. boxes are now typically constructed of plywood or particleboard, more expen- Many companies, however, offer sophis- particleboard topped with , sive cabinets tend to use thicker materi- ticated, layered finishes in many colors vinyl paper, melamine al for cabinet boxes and shelves. or wood tones. or the same kind A solvent-based var- of high-pres- nish is a common

$700 TOP OF THE LINE, WITH A PRICE TAG TO MATCH This Rutt Custom Cabinetry base unit has a sophisticated painted finish and an inset door, making it look more like traditional -grade cabinetry. Good quality hardware operates smoothly. 15, 16 Carcase: The cabinet box is made from -in. veneer-core plywood with a -in. veneered back of medium-density fiberboard. A full dust panel reinforces the $300 top of the cabinet. FOR MORE MONEY, A STURDIER CABINET 17 Shelf: Although the retaining clip on the shelf is plastic, This semicustom KraftMaid cabinet has several advantages over lower-priced the weight is actually carried by a concealed metal pin, alternatives, including heavier materials and more durable construction. which is stronger. Adjustable and 18 in. deep, the shelf is 10, 11 Carcase: This cabinet box is made from -in. veneer-core plywood with a made from -in. veneer-core plywood. -in. plywood back and a fully finished interior. Two -in. plywood stretchers reinforce the top of the cabinet. 18 Drawer: The drawer is made from -in. joined with glue and dowels at the corners with top- 12 Shelf: A -in. plywood shelf runs the full depth of the cabinet. Held in place quality undermount drawer slides. The drawer has a by plastic clips, the shelf is fully adjustable. -in. bottom. 13 Drawer: A dovetailed hardwood drawer box is made with -in. sides with a 19 Door: A traditionally mortised and tenoned door -in. bottom and a -in. hardwood drawer front. frame has a beaded detail on the inside edge and is 14 Door: The solid door frame of -in. has a solid-wood panel on hung with decorative butt hinges, which are not adjustable hinges. adjustable. DRAWERS: A STURDY BOX CAN TAKE A LOT OF ABUSE Few kitchen components get as much wear and tear as a drawer. Before the intro- Doweled hardwood drawer box. Light duction of modern drawer slides, a wood drawer box ran on wooden runners fas- and strong, this -in. box of yellow poplar is joined with dowels at the cor- tened to the inside of the cabinet. Often overloaded and yanked on unmercifully in ners and comes with a -in. plywood drawer bottom. That may be overkill in a sticky summer weather, drawers had a hard life. Good drawer slides incorporating narrow drawer, but a bottom this thick plastic or metal rollers have eliminated much of that stress, making drawer construc- won't sag. Self-closing Blum undermount drawer slides are hidden, and they per- tion less of an issue than it used to be. Even so, a drawer made of undersize material form flawlessly. and running on cheap slides will be a never-ending source of irritation. Solid hardwood traditionally has been the material of choice for good-quality Dovetailed hardwood. Always the darling drawer boxes. One big advantage is that the material does not dictate the joint that of the cabinet trade, a dovetail drawer should last a long time. This one has sides will be used to join the corners of the box. Solid wood can be dovetailed, doweled, of -in. hardwood and a -in. plywood biscuited or dadoed, and a raw edge will never show. Many drawers also are made bottom (a heavier drawer bottom would be better in a wider drawer intended for from : veneered plywood, particleboard, melamine or medium- heavy objects). Undermount slides are density fiberboard. These drawers, common in frameless cabinetry, are often glued out of the way, but they do not operate as smoothly or seem as sturdy as those and doweled together. Raw edges must be banded. Plywood or melamine drawers made by Blum. certainly can be durable, but the material should be at least in. thick. Avoid draw- ers made from thin, vinyl-covered particleboard and nailed at the corners. They feel Marginal materials and construction. Drawers such as these are unlikely to give flimsy, and they are more likely to come apart over time. you a lifetime of dependable service. A standard drawer slide is an epoxy-coated, three-quarter extension unit rated at Faced with a drawer front of red oak, the drawer box is -in. medium-density fiber- 75 lb. But full-extension slides, rated to 100 lb. and allowing access to even the back board faced in wood-grain vinyl and of the drawer, may be available as an upgrade. Undermount slides stay out of sight joined with nails and glue. The -in. drawer bottom flexes under pressure. and, like other hardware, come in various levels of quality. The best are made from heavy-duty materials and quiet, smoothly operating rollers or ball bearings, such as Doweled melamine. Typical for a frame- the Tandem slide by Blum, used on Rutt cabinets. less cabinet, this drawer box is made of -in. melamine, doweled at the corners, Drawers made from wood parts are by far the most common, but metal drawers with a -in. bottom. The three-quarter also are available. One variety found in some frameless cabinetry has epoxy-coated extension epoxy-coated slide (this one by Blum) operates smoothly. The gap be- metal sides attached to a standard melamine drawer front The drawer side incorpo- tween the applied drawer front and the rates part of the slide mechanism. front of this box shouldn't be there.

Where to buy a kitchen Manufacturers sell their cabinets through Web sites where you can browse product For lists of manufacturers, try www. a retail network that includes building- offerings, learn more about how their buildingonline.com or www.kitchen-bath. supply stores, lumberyards and stores cabinets are built and find out where to com. Lists are organized so that you can specializing in kitchen and bathroom cab- buy them. One place to start is with a search for a smaller company in your re- inetry. Larger cabinet retailers offer more search engine such as www.dogpile.com gion. Another good resource is www. variety, and those located near big home- or www.askjeeves.com (or whatever your nkba.org, the home page of the National improvement centers such as Home De- favorite might be), where a search for Kitchen and Bath Association, an industry pot may offer everyone the prices that "kitchen cabinets" will turn up compa- trade group. You'll find design tips, bud- once were reserved for builders. If you nies all over the country. Content can geting information and industry links for have a particular cabinet brand in mind, range from specific information on con- cabinets and other products. The Kitchen the company can provide the name of a struction techniques and materials to Cabinet Manufacturers Association's site nearby retailer. collections of glossy photos. Some cabi- (www.kcma.org) details the association's Driving from store to store is a time- net-manufacturing companies offer in- certification process for kitchen cabinets, honored way to shop, but doing some teractive sites that will help you to de- valuable information for anyone in the homework on the Internet first can help. sign a kitchen layout and to choose market for a new kitchen. Many manufacturers maintain their own various accessories. —S.G.

CABINET DOORS ARE A VISUAL FOCAL POINT Manufacturers devote a lot of attention veneer (photo bottom center). Profiles face of the cabinet, making the cabinet to the doors on their cabinets for good will be crisper, and panels more durable, look more like a piece of furniture. reason: Along with drawer fronts, these when of solid wood. Thermofoil doors Overlay doors are usually hung with parts are dominant visual elements in (photo bottom left) mimic frame-and- cup hinges, which are hidden when the any kitchen. A single company may offer panel styles but are made of engineered door is closed. Cup hinges allow the dozens of door styles. Many cabinet wood covered in plastic. door to be adjusted in several direc- manufacturers do not build their own Some doors have mitered corners, like tions, making alignment easy for manu- doors, buying them instead from ven- a picture frame, which are doweled or facturer and buyer alike. Better hinges dors such as Conestoga Wood Special- splined together. Seasonal wood move- have more adjusting points, and some ties Inc. in East Earl, Pennsylvania, which ment makes this type of joint more like- allow the door to be popped off the makes some 5.5 million doors a year. ly to open up than other designs, just cabinet without using tools (photo top On frame-and-panel doors, virtually like mitered door and window casings. left, facing page). everyone now uses what's called a cope- Most kitchen cabinets have overlay Door hinges can be a trouble spot for and-stick joint in which the interlocking doors, meaning the doors overlap the cabinets. According to the Kitchen Cabi- edges of the frame parts form the glue door opening. A full overlay door, such net Manufacturers Association, failing joint. Although this joint might horrify as the one on the melamine cabinet on hinges are one of the most common traditionalists, it is by now time-tested p. 42, covers the front of the cabinet reasons that cabinets flunk certification and strong enough. Be wary of any door completely. Because the doors are tests. So it pays to check them carefully showing gaps in the joinery. Raised door slightly bigger than their openings, over- when looking for cabinets. Avoid hinges panels may be either solid wood with a lay doors don't require any fitting. Less that have too much play or feel flimsy. profile milled into the outside edge common are inset doors, which are Scott Gibson is a senior editor at Fine Homebuild- (photos bottom right, facing page) or housed in the door opening. When ing. Photos by Scott Phillips, except where noted. engineered wood faced in a thin wood closed, inset doors are flush with the

Thermofoil doors have a core of engi- A stock frame-and-panel door. A solid A step up in a wood design. This maple neered wood. A traditional frame-and- red-oak frame surrounds a veneered pan- KraftMaid door has a solid-wood raised panel look-alike, this door is actually a el. Frame pieces are joined at the corners panel and a smoother, less brassy finish vinyl-like plastic formed around a core of in a cope-and-stick pattern, a standard than the door on a budget cabinet. The medium-density fiberboard milled by a door joint. The panel is a very thin wood cope-and-stick joinery is essentially the computer-controlled . Unlike other veneer over particleboard, not solid same. The color and figure of the maple kinds of laminated doors, this one has on- wood. Some sanding marks are evident pieces used in both the panel and the ly a single seam. MDF is heavy and stable. on the inside of the door. frame are not perfectly matched. Easy on and off. This cup No adjustments. This Adjustable cup hinge. This Traditional butt hinge. A hinge allows a door to be economy hinge offers no style of cup hinge allows furniturelike hinge on this popped off without tools. door adjustments, and it the door to be adjusted in door is set into a mortise flexes under a load. two directions. in the frame.

Old- style detailing in a painted door. This door uses more traditional joinery. Its sand-through finish relies on layers of color and paint, plus sanding, to mimic the effects of years or hard use.