Outdoor Cabinetry - Finish Carpentry - Contractor Talk

Outdoor Cabinetry

 
Thread Tools Search this Thread Display Modes
Old 03-29-2014, 12:57 PM   #1
Maker of fine kindling
 
Gus Dering's Avatar
 
Trade: cabinet maker
Join Date: Oct 2008
Location: Santa Rosa CA
Posts: 6,199
Rewards Points: 12,490

Outdoor Cabinetry


We have done pool house cabinets before but they were always well under a roof. This kitchen will be partially out in the open. The grill wall is completely outside the building line.

At first I just refused to be involved. I just dint want the liability of a wood cabinet out in the elements. I pushed hard for the designer to find some stainless cabinetry and take me out of the picture all together. But that plan just kept failing. They really wanted a continuous cabinet line from inside to outside and the stainless idea never took hold. This pool house is just a very small portion to the large house full of cabinetry happening at the same time. I was forced into looking deeper for a viable solution. I think I have it worked out.

I ended up looking deeper into using King Starboard for the box parts.
http://www.kingplastic.com/products/...-starboard-st/

I found enough material locally that was special ordered by a shop that went bankrupt leaving the supplier holding the 10 sheets of Dolphin Grey collecting dust in their where house. That was a good score. Design team was good with using that for the interiors.

After researching the proper tooling for use on the cnc, this stuff was not that much different than wood to machine. The machine time was increased considerably. One sheet had a run time of an hour and ten minutes. This due to the reduced rate of feed and the need for multiple passes. One learning curve about using the proper drill bit set me back a day awaiting the proper plastic cutter bit. The standard brad point bit clogs with the curly shavings to point where it damages the surface of the material. The spear shaped plastic bit ejects the shaving very well. But peppers the spoiled board with deeper holes than normal, no big deal though.



Outdoor Cabinetry-image-1652538845.jpg



Outdoor Cabinetry-image-3903572924.jpg



Outdoor Cabinetry-image-2476126844.jpg
__________________
Every parent who has walked barefoot into their child's room late at night hates Legos
Gus Dering is offline  
The Following User Says Thank You to Gus Dering For This Useful Post:
marcsmith (03-29-2014)

Warning: The topics covered on this site include activities in which there exists the potential for serious injury or death. ContractorTalk.com DOES NOT guarantee the accuracy or completeness of any information contained on this site. Always use proper safety precaution and reference reliable outside sources before attempting any construction or remodeling task!

   

Advertisement

 

Old 03-29-2014, 09:11 PM   #2
Pro
 
Trim40's Avatar
 
Trade: Guy who plays with wood
Join Date: Jan 2009
Location: Littleton , CO
Posts: 1,107
Rewards Points: 550

Re: Outdoor Cabinetry


Cool looking stuff. Keep the drawers closed on windy days, those slides might get a little crunchy.

Advertisement

Trim40 is offline  
Old 03-29-2014, 09:32 PM   #3
Pro
 
CarpenterSFO's Avatar
 
Trade: GC
Join Date: Dec 2012
Location: CA
Posts: 7,076
Rewards Points: 2,044

Re: Outdoor Cabinetry


The boxes are made of the StarBoard, and if I see it correctly the face pieces are wood? How have you handled the weathering issue with the designers and customer, for the pieces that are outside?
__________________
- Bob
CarpenterSFO is offline  
Sponsored Links
Advertisement
 
Old 03-29-2014, 09:40 PM   #4
designer + carpenter
 
NINZAN STUDIO's Avatar
 
Trade: carpentry
Join Date: Jan 2012
Location: FL
Posts: 556
Rewards Points: 510

Re: Outdoor Cabinetry


Gus - we design and order our outdoor cabs made from the same material (Kingboard or Starboard, one is a heavier variety). I checked into sourcing it from a regional distributor once, you have to buy a pallet full to make it economical. Hardware including drawer guides has to be all stainless. Doors and drawer front usually teak or cypress.
NINZAN STUDIO is offline  
Old 03-29-2014, 09:42 PM   #5
Pro
 
TimelessQuality's Avatar
 
Trade: GC/Remodeling
Join Date: Sep 2007
Location: Central America (Kansas)
Posts: 4,732
Rewards Points: 1,730

Re: Outdoor Cabinetry


Gus is ready to take on the boating market
__________________
-Steve

'It takes considerable knowledge just to realize the extent of your own ignorance.'-Thomas Sowell
TimelessQuality is offline  
Old 03-29-2014, 11:36 PM   #6
Maker of fine kindling
 
Gus Dering's Avatar
 
Trade: cabinet maker
Join Date: Oct 2008
Location: Santa Rosa CA
Posts: 6,199
Rewards Points: 12,490

Re: Outdoor Cabinetry


All the slides and hinges are stainless. The drawer banks are under roof.

I have to paint the fronts so initially I went with Extera. I have not used that before and did some research about it and everywhere I looked I found favorable opinions about it. We cut all the filler parts, doors and drawer fronts on a Friday. Took a small scrap piece, miked it for thickness and placed it in a bucket of water for the weekend. The water barely soaked in at all and only gained about .005 in thickness. Great right?

But the doors turned into potato chips. Look at this picture of the parts on a cart.



Outdoor Cabinetry-image-3671155506.jpg

While researching my options for the painted parts I talked to my two two plywood salesmen and both thought the Extera would be the best with the imported birch with marine grade glue as a close second. So I ordered a couple sheets of the birch and recut the doors and drawer fronts. The fillers are fine in the Extera. I have not done the same water test on the birch. Maybe in part because I don't want to know the result because I don't have a third option.

The paint job will be back brushed for a fair amount of brush stroke to show. My finisher is still working on the best choice of paint for this. I'll post up what we come up with when it's decided.

How I sold myself on this job is that all of these painted elements can be easily repainted or replaced if necessary. But the boxes are good for ever. I guess time will tell. In the mean time, I'm sleeping ok. I never sleep all that well though :-)
__________________
Every parent who has walked barefoot into their child's room late at night hates Legos
Gus Dering is offline  
The Following User Says Thank You to Gus Dering For This Useful Post:
CarpenterSFO (03-30-2014)
Old 03-31-2014, 06:31 PM   #7
Pro
 
alboston's Avatar
 
Trade: General Contractor
Join Date: Feb 2007
Location: Duxbury/Marthas Vineyard
Posts: 634
Rewards Points: 686

Re: Outdoor Cabinetry


Nice looking cabinets. Around here, a 4x8x3/4 sheet of starboard goes for $350/sheet.
alboston is offline  
Old 03-31-2014, 09:22 PM   #8
Maker of fine kindling
 
Gus Dering's Avatar
 
Trade: cabinet maker
Join Date: Oct 2008
Location: Santa Rosa CA
Posts: 6,199
Rewards Points: 12,490

Re: Outdoor Cabinetry


Quote:
Originally Posted by alboston
Nice looking cabinets. Around here, a 4x8x3/4 sheet of starboard goes for $350/sheet.
Yes, it's expensive compared to plywood. I don't think it's a fair comparison though. I think you need to look at stainless steel or some other decay proof material. If you have an alternative with similar features, I'm all ears. I couldn't find it and I looked pretty hard.

This time I ran across 10 sheets of 5x7x3/4 in dolphin gray for about $225 a sheet. I only needed eight so there are still two sheets in Sacramento if you are interested :-) But in the future if someone wants me to do cabinets completely out in the open, they will either pay for the starboard boxes or find their cabinets else where. I need to feel good about what I put out there or it doesn't go out at all.

Advertisement

__________________
Every parent who has walked barefoot into their child's room late at night hates Legos
Gus Dering is offline  
The Following 3 Users Say Thank You to Gus Dering For This Useful Post:
alboston (04-01-2014), bmcquin (04-01-2014), Lester P. (04-02-2014)


Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Join Now... It's Fast and FREE!

I am a professional contractor
I am a DIY Homeowner
Drywall Talk is for
PROFESSIONAL CONTRACTORS ONLY!

At DrywallTalk.com we cater exlusivly to professional contractors who make their living as a contractor. Knowing that many homeowners and DIYers are looking for a community to call home, we've created www.DIYChatroom.com DIY Chatroom is full of helpful advices and perfect for DIY homeowners.

Redirecing in 10 seconds
No Thanks
terms of service

Already Have an Account?