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Cupboard doors – renovation

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Cupboard doors – renovation

Postby Phil » 04 Dec 2016, 09:20

Cupboard doors – renovation

Eldest son and DIL bought an ‘old’ house, about 45 years old, that requires some serious TLC.
Fairly large with 4 bedrooms.

The previous owners, elderly couple, did no maintenance, so the house really looks shabby inside and outside.

The built in cupboards in the bedrooms and passage have very thick veneered doors (hollow core) which were installed badly and also covered with a thick layer of varnish or PU.

The veneer is Mahogany which on the outside of the door has faded to a nice light colour, the inside panel still very dark. Important to remember for filler and stain colour.

The hinge recess on the doors are either too deep or too shallow. They must have used a blunt screwdriver to cut them.

When you push the door closed, it jumps back due to bad hinge installation.

When the frames for the built in cupboards were painted, the edges of the doors also got paint. No care or finesse.


Digressing – bathroom 2 shower door.

The foot plate was installed the wrong way around, so when you showered the water ran out onto the floor (for 40 years?!)

When they installed it they did not realise you can turn it the other way and just change the fixed panel to the other side and the other panels slide to the other side.

I spent a Saturday dismantling this lot and cleaning off 40-year-gunge.

The footplate when I eventually got it out was tiled in! Turning it around was not an issue. I reinstalled filling the gap with silicone sealer and pop riveted the frame back in.

There is only a ‘very slight’ drip on one corner, but it will have to do till they renovate the bathroom.


Ok, back to the cupboard doors.

Bedroom 4 were the first doors he took off.
Three large and three small doors.

You learn from your mistakes.

1) Assess the door closed and mark where edges have to be trimmed for a better fit.

2) Mark the flipping hinges!!! Which door, which position. He only realised this when fitting back the doors after I had finished with them.

The three large doors are quite heavy and bulky to handle. Transporting the doors is not a problem as I have an NP200 pickup.

The easiest way to do the ‘renovation’ is on a nice large flat surface – enter the fold up trestle table, which takes up my half of the garage. I now park outside.

The work involved is quite simple and messy.
The tools are laid out on the back of the table.

Makita third sheet sander for 220grit
Makita half sheet sander for 180 grit
Ryobi belt sander with 100 grit for top, bottom and hinge sides
2 putty knives for filler
2 G-clamps and pads (to stop the door moving around)
2 Sash clamps for loose edges
Filler – Mahogany for front and dark Oak for back
Packet of Stanley blades
Teak stain – colour closest to the Mahogany on the outside
Walnut stain – colour closest to the Mahogany on the inside
Large packet of 180 and 220 grit paper & sanding block
Steel ruler – long & short
Marking pen – fine point
Stanley knife to cut the sandpaper
Hearing protection! (belt sander)

Process:-
Drill out screws stuck in hinges, plug hole with a dowel or glue in new larger plug – I used some scrap Beech.

This is the door with the hinge that required drilling out.

Image

Glue and clamp any loose side strips. (sash clamps)

Image

Mark the edges, on the hinge side, that need to be trimmed for a better fit. This is where the belt sander, as opposed to a planer, is used.
So easy to sand off 1mm and also clean up the top and bottom edges.

The hinge is then checked for unevenness/too deep a fit.
A bit of chisel work and some filler sorts out any problems.

Now to the surface of the door - examine the surface for dings and scratches. This is where my friend Stanley-the-blade is used to ‘soften’ the scratch or ding.

Next up the big Makita with 180 grit.
When I bought the Makita it did not have a hole-maker and they did not stock one, so next best thing was make one.

Image

A bit crude, but it works. Place the paper face up, put the peg board on top and press.
Voila! One half holy sheet.
It also did not come with a dust bag, but the bag from the smaller Makita fits of.

Some elbow and back movement with the sander up and down the door until the whole surface has been sanded. Remember, no pressure, the sander will do its thing.

A wipe off with a damp cloth, and when dry, all the ‘hollow’ areas are visible. These are then tackled by hand sanding.

Now to address all the screw holes as well as the lock and handle holes.
The screw holes are easy, clean them out with the vac and press some filler in.

For the lock/key hole I stuff some tissue in about 15mm down, this gets removed when I do the other side. Then gradually start back filling with filler until level.

Stanley-the-blade is again used to check the scratches and dings, and also a bit of hand sanding.

Next up is the small Makita with 220 grit. This comes with its hole maker, fit the paper on the sander, apply the hole maker, press down and you are A-for-away.

Image

After sanding wipe dust off with a damp cloth.

Again Stanley and sandpaper by hand.
Double check the screw holes and the lock/key hole to ensure they are level with the surface.

Snags – where the handles and locks are removed from the face of the door, and any stickers stuck on, the colour of the veneer remained dark.
No amount of sanding or whatever lightens it up.

This is not too serious where the handles were, as the new handle hides the marks.
However the one door had a round sticker on it which will be very visible once the door has been sprayed. They can maybe hang a mirror on that door?

Image

Here are 2 of the doors for bedroom 4 that I completed some time ago. They are ready for spraying, will post pics when completed and installed.

Image

Thank you for reading

Cheers
Phil
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Re: Cupboard doors – renovation

Postby Rod » 04 Dec 2016, 13:07

That looks like a lot of hard work - what fathers will do for daughters
I like the homemade hole punch.
My daughter had some work done a few years ago by a local builder including a new upstairs bathroom. Recently the shower started leaking through the ceiling. On investigation they found that the tiles had been stuck directly onto ordinary plasterboard which had rotted and gone mouldy! The builder supposedly had a good reputation but not anymore

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Re: Cupboard doors – renovation

Postby Malc2098 » 05 Dec 2016, 18:28

Nicely elegant solution to make the holes!
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Re: Cupboard doors – renovation

Postby Phil » 06 Dec 2016, 07:40

Rod wrote:That looks like a lot of hard work - what fathers will do for daughters

Rod



This is for eldest son and DIL - he was going to do the sanding himself with a small Skil sander.
I offered and it was the right opportunity to buy a belt sander 8-)


Rod wrote:I like the homemade hole punch.

Rod



Malc2098 wrote:Nicely elegant solution to make the holes!


It works "ok" not quite 100% lined up to the holes. When I can find a round-tuit I will either fiddle it right or just make a new one.
Because the holes don't line up 100%, the dust extraction does not work the way it should.

He was going to buy a Makita one-third sander, so being a good parent, I gave him mine. :D

And went and bought a new one. 8-) 8-)
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Re: Cupboard doors – renovation

Postby Phil » 11 Dec 2016, 10:06

The total project is:-

Bedroom 1 – zero doors. The cupboards were broken out to enlarge the bathroom and new cupboards will be installed. Melamine on PB.

Bedrooms 2, 3 and 4 all have 3 large doors and 3 small doors.

Passage - 2 large and 2 small doors. These doors are 140mm wider than the bedroom doors, and heavier.

Study – can’t remember, could be 2 large & 2 small.

These are the 3 small doors at the top of the bedroom cupboards.

Image

Same process as the big doors, just easier to handle.

Current status:-

Bedroom 2 – in progress
Bedroom 3 – doors still to be taken off
Bedroom 4 – completed
Passage – in progress

The inside of the cupboards were finished off with Pine boards about 18mm thick, which were all ripped out.


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Re: Cupboard doors – renovation

Postby Phil » 02 Jan 2017, 06:43

The door with the mark on it from a sticker.

Image

The final decision reached during the week was to ditch it. (great pity as both doors were completed ready for spraying)

So I went and fetched another set of doors that were removed from bedroom 1.

Another decision – take the left and right doors so that the colours/shade are fairly close.

Condition looks ok, just one screw to drill out and plug the hole.

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Re: Cupboard doors – renovation

Postby Phil » 03 Feb 2017, 11:50

The final finish will be a clear matt PU.
This will be applied with a spray gun.

Big question – where to do it?

The compressor is at his house and the rest of the kit in my garage.

Easy decision – his garage. Rather have all the mess there, especially the fine overspray dust. :D
Also the completed doors don’t have to then be transported.

I tackled this the same way as the kitchen cupboard doors at the old house.

Place cardboard boxes on the floor to lay the doors onto.
They need to be spaced so that you can get in between with the pipe and the compressor.

All 6 doors were done at once, easier for cleaning the gun.

My spray gun is a top feed unit, plastic cup so you can see the level, and does not splutter and spit when running dry.

Unless you do this kind of work regularly, you tend to forget minor things – like don’t shake it, there are drops that come out from the breather hole and splatter onto the nicely sprayed surface!

The doors get three coats, with an 800 grit rub between each coat.

Final inspection outside in sunlight showed like a freckle on the surface. Once in the house, not noticeable at all.

Discussed this ‘freckle’ with one of the chaps at work who sprays cars. He says its fine bits of residue in the PU from maybe some skin forming.
Solution is to place a filter over the cup and then fill it up.

I will buy a filter before I do the next lot of spraying.

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Re: Cupboard doors – renovation

Postby Phil » 19 Feb 2017, 12:11

These are bedroom 4 doors completed and fitted.

All the sanding marks and patches disappear when sprayed.

Image

The new handles are the medium size barrel handles.

On the top doors the handles were placed close to the bottom, so it’s easier to open the door.

This is what the inside of the cupboards looked like (one of the better ones)

Image


He measured and fitted the insides himself, melamine on PB. The larger hardware stores do cut to size and edging per your measurements.


Image


Image


Image


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Re: Cupboard doors – renovation

Postby Andyp » 19 Feb 2017, 14:07

Well worth the effort Phil.
cheers

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Re: Cupboard doors – renovation

Postby Phil » 19 Feb 2017, 14:46

Thanks Andy.

Busy with the last of the passage doors which are being painted, so have to make sure all the holes, dings and chips are all filled properly. Just using any colour filler, and then they get a sealer before the undercoat.
I stop at the undercoat, he must hang them, undercoat any marks and then paint the same colour as the walls.

I need to extract digit as I need them completed by Wednesday. Going for my other eye op on Thursday and certainly do not want to mess around with any dust for a while.
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Re: Cupboard doors – renovation

Postby MattS » 20 Feb 2017, 15:07

Good work - I'm going to be going through similar except in my own house. The previous owners replaced the original 60's doors like those with horrid pine doors which are now bright orange. I managed to get 8 doors free from a development property, really nice high quality doors better than would have been in the house originally but they're all slightly off in size and need new hinges etc. so not an easy task.

Everyone thinks we're mad wanting to put 60s features back in :lol:
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Re: Cupboard doors – renovation

Postby TrimTheKing » 20 Feb 2017, 16:39

MattS wrote:...Everyone thinks we're mad wanting to put 60s features back in :lol:


I have to say, while I think Phil's work on restoring these has been extremely well done, I think the finished product is (In my opinion of course) ugly as all sin! They are exactly the kind of thing I ripped out of our first house as my first job. :?

Would be a boring life if we all liked the same stuff though eh.

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Re: Cupboard doors – renovation

Postby Tusses » 20 Feb 2017, 16:55

TrimTheKing wrote:
MattS wrote:...Everyone thinks we're mad wanting to put 60s features back in :lol:


I have to say, while I think Phil's work on restoring these has been extremely well done, I think the finished product is (In my opinion of course) ugly as all sin! They are exactly the kind of thing I ripped out of our first house as my first job. :?

Would be a boring life if we all liked the same stuff though eh.

Cheers
Mark


lol .. as JaJaBinks would say .. How woooooood ! lol

I like it for what it is :-)
I even thought they might look nice as table tops
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Re: Cupboard doors – renovation

Postby TrimTheKing » 20 Feb 2017, 16:58

I hope it's not taken as rude… There's plenty of things in this life that are regarded as classics and to my eye/taste, are horrible. It doesn't mean I think I'm right…

I just think most things 60's come from a time of extremely poor design taste and there's very little from around that time that I like from both an architecture and furniture perspective.

I don't have anything against anyone else liking them though… :oops: :obscene-drinkingcheers:

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Re: Cupboard doors – renovation

Postby Tusses » 20 Feb 2017, 17:27

it was said in jest .. ala the JAJA ref ! :-)

it is to a taste .. as is most things in life : :eusa-dance:
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Re: Cupboard doors – renovation

Postby TrimTheKing » 20 Feb 2017, 17:58

Tusses wrote:it was said in jest .. ala the JAJA ref ! :-)

it is to a taste .. as is most things in life : :eusa-dance:


Yep appreciate yours was in next mate, just wanted to make sure Phil didn't take it any other way. ;)

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Re: Cupboard doors – renovation

Postby MattS » 20 Feb 2017, 20:43

TrimTheKing wrote:I hope it's not taken as rude… There's plenty of things in this life that are regarded as classics and to my eye/taste, are horrible. It doesn't mean I think I'm right…

I just think most things 60's come from a time of extremely poor design taste and there's very little from around that time that I like from both an architecture and furniture perspective.

I don't have anything against anyone else liking them though… :oops: :obscene-drinkingcheers:

Cheers
Mark


:lol: I have to say I like a lot of mid century design and architecture, including the 60s. There was an amazing house in the RIBA house of the year shortlist which was a refurb of a piece of good 60s architecture, I suspect you wouldn't like it, as you say we can't all like the same stuff! Horses for courses!

The other thing is I'm quite particular about authenticity and originality. Both my wife and I were children of the 80s and 90s. My wife's parents bought a run down 30s property and ripped out a lot of features to suit current fashion. Maybe 60s won't be desirable to the same level but if everyone them out then you loose a bit of history.

Anyway sorry for taking the thread of topic!
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Re: Cupboard doors – renovation

Postby Phil » 23 Feb 2017, 09:34

TrimTheKing wrote:
Tusses wrote:it was said in jest .. ala the JAJA ref ! :-)

it is to a taste .. as is most things in life : :eusa-dance:


Yep appreciate yours was in next mate, just wanted to make sure Phil didn't take it any other way. ;)

Cheers
Mark


Mark, no problem I will sit in the corner and sulk. :( for maybe 2 seconds :lol:

I will say one thing for those doors, they will last another 40 years compared to the PB-Melamine C R A P we have in our new house with funny hinges that need adjusting.
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Re: Cupboard doors – renovation

Postby Phil » 23 Feb 2017, 09:38

MattS wrote:
Anyway sorry for taking the thread of topic!


You are not really off topic, all relates back to the doors.

Of which the last passage one has had no work on it this week.
Due to writing reports and having the electrician here sorting out their mess before the inspector will issue a new COC. (another topic later)
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Re: Cupboard doors – renovation

Postby Phil » 05 Mar 2017, 13:26

Some more boring work …………………….

The passage cupboard doors are being painted the same colour as the walls (passage is quite dark), therefore require a lot more attention to filling and sanding the dings and scratches.
I was more aggressive with the sanding starting at 100 grit and then moving up through the grits.
Once sanded and patched, a coat of sealer was applied and a fine sanding to denib brush and dust spots. On top of that was a coat of universal undercoat, lengthwise, with some tint bringing the colour a lot closer to the final coats.
Again a fine sanding and then another coat across the width with another sanding and also some scraping with the Stanley blade to get rid of any brush marks. Turn it over and repeat for the other side.


Image

Image


One large door and the two small ones completed. The second large door will be completed when I am allowed back into the garage. (the eye op was a lot bigger and more stressful than the last one)

Thank you for reading
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