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Making Curved Doors Sierra Vista 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).

The Home Depot
(520)439-2806
3500 Avenida Cochise
Sierra Vista, AZ
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

Kmart 3695 / Cross Merch
(520) 459-0345
2011 E Fry Blvd
Sierra Vista, AZ
Store Hours
Miscellaneous
Store Type
Miscellaneous
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

Lowe's
(520) 439-3640
3700 Martin Luther King Parkway
Sierra Vista, AZ
Hours
M-SA 6 am - 9 pm
SU 7 am - 8 pm

Foxworth Galbraith- Huachuca City
520-456-1200
698 N. Gonzales Blvd Huachuca City, AZ, 85616
Huachuca City, AZ
 
Energy Smart Concepts Inc
(520) 459-1997
www.iamenergysmart.com
Sierra Vista, AZ
 
Lowe's of Sierra Vista, AZ
520-439-3640
3700 Martin Luther King Parkway Sierra Vista, AZ, 85635
Sierra Vista, AZ
 
The Mall Of Sierra Vista
(520) 515-3200
2250 El Mercado Loop
Sierra Vista, AZ
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:10-21
Sun:12-18
Store Features
Mon:10-21
Tue:10-21
Wed:10-21
Thu:10-21
Fri:10-21
Sat:10-21
Sun:12-18

Sierra Vista Ace Hardware
(520) 458-3650
3756 E Fry Blvd, Corner of Fry Blvd & Hwy. 92
Sierra Vista, AZ
 
B & D Lumber And Hardware
(520) 432-4272
93 Bisbee Road
Bisbee, AZ
 
Mountain View Air Conditioning & Heating, LLC
(520) 226-4299
3410 E. Canyon De Flores
Sierra Vista, AZ
Services Offered
HVAC Contractor, Heating contractor

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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