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Making Curved Doors Sheboygan WI

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).

The Home Depot
(920)451-0624
4025 Highway 28
Kohler, WI
Hours
Mon-Sat: 6:00am-9:00pm
Sun: 8:00am-8:00pm

Kohler Memorial Mall
(920) 208-2000
3347 Kohler Memorial Dr
Sheboygan, WI
Store Hours
Sears Stores
Store Type
Sears Stores
Hours
Mon:10-21
Tue:10-21
Wed:10-21
Thu:10-21
Fri:10-21
Sat:9.5-20
Sun:11-18
Store Features
Mon:10-21
Tue:10-21
Wed:10-21
Thu:10-21
Fri:10-21
Sat:9.5-20
Sun:11-18

Plymouth - Dlr In Kmart
(920) 893-4900
2615 Eastern Ave
Plymouth, WI
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:8-22
Tue:8-22
Wed:8-22
Thu:8-22
Fri:8-22
Sat:8-22
Sun:8-21
Store Features
Mon:8-22
Tue:8-22
Wed:8-22
Thu:8-22
Fri:8-22
Sat:8-22
Sun:8-21

1150 Service Road
(920) 894-2352
Suite 2
Kiel, WI
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:10-19.5
Tue:10-19.5
Wed:10-19.5
Thu:10-19.5
Fri:10-19.5
Sat:9-18
Sun:12-17
Store Features
Mon:10-19.5
Tue:10-19.5
Wed:10-19.5
Thu:10-19.5
Fri:10-19.5
Sat:9-18
Sun:12-17

Koeppen Do it Best Hardware
(920) 773-2330
203 S Fourth Ave
St Nazianz, WI
 
Trilling True Value Hardware
(920) 457-5541
901 Michigan Ave
Sheboygan, WI
 
Daane Ace Hardware
(920) 564-2338
936 Center Ave
Oostburg, WI
 
Lulloff True Value Hdwe
(920) 894-3236
203 Fremont St
Kiel, WI
 
Doegnitz Ace Hardware
(920) 994-9212
115 Allen St
Random Lake, WI
 
Belgium Hardware
(262) 285-3214
756 Main St
Belgium, WI
 

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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