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Making Curved Doors Greeneville TN

Curved doors and panels add elegance to any project, especially kitchen cabinets. Making these complicated parts requires careful planning and building. The task can be made much easier by using a flexible panel product called Kerfkore (see photo, below left).

Full Cycle Woodworks Inc.
(423) 272-9004
1600 Hwy 70 North
Rogersville, TN

Data Provided by:
Ace Hardware
(423) 639-6223
1023 W Main St
Greeneville, TN
 
LOWE'S OF GREENEVILLE, TENN.
423 639-0012
2375 EAST ANDREW JOHNSON HIGHWAY GREENEVILLE, TN, 37745
Greeneville, TN
 
Lowe's
(423) 788-7000
1498 E. Jackson Boulevard
Jonesborough, TN
Hours
M-SA 7 am - 9 pm
SU 8 am - 7 pm

Appalachian Stoneworks
(866) 389-4260
412 Kinchloe Mill Rd
Jonesborough, TN

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Fastenal- Greeneville
423-638-3622
730 W. Andrew Johnson Hwy Greeneville, TN, 37743
Greeneville, TN
 
Lowe's
(423) 639-0012
2375 East Andrew Johnson Highway
Greeneville, TN
Hours
M-SA 7 am - 9 pm
SU 9 am - 7 pm

Kmart 3773 / Cross Merch
(423) 636-1118
1355 Tusculum Blvd
Greeneville, TN
Store Hours
Miscellaneous
Store Type
Miscellaneous
Hours
Monday To Friday Working Hours is :8-22 and for Sat:8-22
Sun:8-21
Store Features
Monday To Friday Working Hours is :8-22 and for Sat:8-22
Sun:8-21

Olde Towne Ace Hardware
(423) 913-1606
220 N 2nd Ave
Jonesborough, TN
 
The Home Depot
(901)475-0438
110 Holly Grove Road
Covington, TN
Hours
Mon-Sat: 6:00am-9:00pm
Sun: 8:00am-8:00pm

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Making Curved Doors

Making Curved Doors

Kerfkore flexible panels handle curves with ease.

by Brad Holden

Curved doors and panels add elegance to any project, especially  kitchen cabinets. Making these complicated parts requires careful planning and building. The task can be made much easier by using a flexible panel product called Kerfkore (see photo, below left). It follows the same principle that cabinetmakers use when they saw multiple kerfs on the back of a piece of plywood to make it flexible. A disadvantage to this saw-kerfing method is the risk of the face veneer cracking or kinking at the kerfs, spoiling the curve’s smooth surface. Kerfcore’s advantage is that that the kerfing is done for you. Its flexible paper backing provides a smooth surface to attach your veneer. 

There are several important tricks and techniques to working with Kerfkore but it’s a surprisingly easy material to work with. I’ll walk you through the main steps of making a curved door with Kerfkore from layout to final trimming. Information on using Kerfkore in other applications can be found at the Web site www.kerfkore.com.

What is Kerfkore?

Kerfkore is a very flexible panel made of 3/8-in.-wide ribs spaced 1/8 in. apart on a paper backer sheet. The spaces between the ribs allows the board to flex. The flexible backer sheet provides a smooth surface for veneering. The ribs in different Kerfkore products are made of particleboard, luan plywood, poplar plywood, MDF, fire-rated treated particleboard or lightweight styrene foam. These different cores have different weights, strengths and screw-holding characteristics. The particleboard core works well for general-purpose doors, such as those for kitchen cabinets. 

Kerfkore with paper backer on both sides is also available. This makes the material more rigid and somewhat easier to handle and enables you to create a curve that turns into a straight run. To make the two-sided variety bend, you cut the backer on one side with a utility knife where you need the bend to occur. 

Kerfkore comes in 4-ft. by 8-ft. sheets in 1/4-in., 3/8-in., 1/2-in., 5/8-in. and 3/4-in. thicknesses and costs between $40 and $125 per sheet (see Sources, below). 

Pick Your Veneer

Photo 1: Your three main veneer choices are two-ply wood veneer (shown here), phenolic-backed (plastic-laminate) wood veneer or vertical-grade plastic laminate. The two-ply veneer is the most flexible of the three and is easily cut with a utility knife or scissors. The phenolic-backed veneer and plastic laminate must be sawn or scored and snapped. The cut edge of the two-ply veneer leaves a dark line that may show on your finished door, depending on the wood species and the finish you apply. The phenolic-backed veneer and plastic laminate both leave a black edge line. 

Make a Full-Size Drawing

Photo 2: Use a top-view drawing to determine the size of the Kerfkore panel and the angles at the edges. T...

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