American Woodworker
Contact Us | Help | Report a Bug
Sign in | Join
 

Making Curved Doors Kingman AZ

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).

Kingman - Auth Hometown
(928) 753-6281
3115 Stockton Hill Rd
Kingman, AZ
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:9-19
Tue:9-19
Wed:9-19
Thu:9-19
Fri:9-19
Sat:9-18
Sun:11-16
Store Features
Mon:9-19
Tue:9-19
Wed:9-19
Thu:9-19
Fri:9-19
Sat:9-18
Sun:11-16

Kingman Tools Plus
(928) 753-2444
117 6th Street
Kingman, AZ

Data Provided by:
The Home Depot
(602)605-8690
5230 W Baseline Road
Laveen, AZ
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(480)988-6810
7401 S Power Road
Queen Creek, AZ
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

The Home Depot
(928)556-1529
1325 W Route 66
Flagstaff, AZ
Hours
Mon-Sat: 6:00am-9:00pm
Sun: 7:00am-8:00pm

Kmart 9528 / Cross Merch
(928) 757-3202
3340 E Andy Divine Ave
Kingman, AZ
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

The Home Depot
(520)877-3533
10855 N Oracle Rd
Oro Valley, AZ
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

Woodcraft - Tucson
(520) 742-9663
6230 North Oracle Road #100
Tucson, AZ

Data Provided by:
The Home Depot
(928)649-3758
1030 S State Route 260
Cottonwood, AZ
Hours
Mon-Sat: 6:00am-9:00pm
Sun: 7:00am-8:00pm

The Home Depot
(623)587-9222
35050 N North Valley Pky
Phoenix, AZ
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

Data Provided by:

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...

Click here to read the rest of the article from American Woodworker