Kitchen cabinet drawer rebuild now complete… I think.

[routlaw]

Some of you might have seen my recent post on another thread, Shake Rattle and Roll, regarding items including screws etc coming loose while towing. My situation had become considerably worse as previously stated in regards to the entire set of drawers and associated hardware with the kitchen cabinet drawers. Cutting to the chase I had to replace all of the soft close glides for a litany of reasons which I will detail below then rebuild and redesign the entire drawer setup and arrangement. Some of the glides had corroded severely preventing their ease of use, and in other cases the boxes themselves were made in what can only be described as sloppy construction, inconsistent sizes, and most of them considerably too small for their respective cabinet openings allowing for the glides to come completely out of, or off their rails. If this isn't enough the cabinets themselves were built out of square, out of plumb, and not parallel from front to back or side to side. 

Hopefully this will provide help to those who might be having some of the same issues. Let me know if you have any questions be glad to help if I can.

For starters attached are some photos of the errant issues we were having.

Image below illustrates how poorly this set of drawer glides were installed which of course imposed a closed drawer that pointed downward, top portion closed while the bottom tilted outward. 

The red arrow on this drawer points to the corroded glide rail. This is the worst example in all fairness. 

closer detail that illustrates the above perhaps better.

In the photo below you can see where these drawers were only stapled together and with no glue anywhere. To make matters worse the cheap plywood used for the plastic face frame inserts was never treated for moisture and thus over a period of time would expand contract then warp and pull away from the drawer box itself. The only method for installing these drawer faces was nothing more than caulk, no screws nothing to hold them in place over a period of time in different weather or humidity patterns. Effectively each of the faces had warped convexly as seen in this photo. 

This is an example of the old drawer boxes once the plastic fronts were removed with scrapers, pry bars and chisels. Note how the 4 inch drawer is 1 inch longer than the 6 inch drawer, and this was consistent throughout for no discernible reason that I could determine. All of my new drawers are a full 20 inches long with the exception of the 12 inch drawer that mounts under the kitchen sink otherwise it would collide with the sink drain, probably not a good idea. 

Most but not all of these plastic face mounts to the drawers are cracked severely or in some cases mild cracks as illustrated below. Eventually I will replace all of the drawer faces with something else in the future and just be done with the cheap 1/2 inch plywood glued/caulked into these plastic cavities.

Now for the rebuild. Below you can see where the drawer positioning is much different. Rather than the 4 inch depth drawer to 6 inch depth drawer, then back to the 4 inch on the bottom row it seemed to make much more sense to do two rows of 4 inch drawers (with 6 inch face fronts) then install the 6 inch drawer with 8 inch front on the bottom row. In addition the upper right drawer as originally installed was only 12 inches deep much like the drawer that mounts underneath the sink. This made no sense to me because there was plenty of room for a full 20 inch drawer to easily slide beneath the cooktop stove. In order to make sure there would not be an overheating issue I ran the both burners for a period of time with my hand touching the bottom of the stove. Never even got warm. It is important to note this stove is built with a second dead air space layer. This allows for much better usage of kitchen tools and storage.

 

Details from the rebuild. Basically I used Kreg Pocket Hole jigs and screws to build the boxes but also used reinforcements below with right angle corner hardware and ran a bead of hot wax glue across all of the underside of the boxes/drawers. Materials were half inch baltic birch plywood, with 1/4 inch birch plywood bottoms dado'ed into the sides and fronts. 

Closeup detail of hardware and messy hot wax glue. I also used a small painters palette knife to spatula the glue while still hot and pliable further into each joint. It was fairly easy to run the heat gun for 6-8 inches of glue line then press the glue further into position, then start on the next 6-8 inches. Pocket holes can be seen in the photo below. 

To mount the face fronts back onto each drawer I used 3/4 inch Big Timber screws that are self tapping, however in order make sure they were solid each drawer front was clamped to its respective drawer during installation of screws. As you can see each screw is counter sunk as well allowing for a deeper bite. Note didn't want to glue them on in addition to screws knowing I would eventually replace the fronts with completely new materials.

The photo below shows two sets of new drawer glides installed properly that being with front of the glide recessed approximately 1/16th of an inch as illustrated by the red circles, not the full 1 inch as originally installed by Oliver. By installing the glides so far back into the cavity of the cabinet boxes the glides would never fully come to their closed positions. Not sure why the water hoses to the kitchen faucet were installed to the front of the rear cabinet brace at the back as seen in this photo. There was plenty of room to route those blue and red lines between the hull and cabinet which I just might do the future. It is also worth pointing out the opening space on the plastic trim for the cabinets is about 1/4 to 3/8 th's different from right to left side which translates into building each side with different width drawers. The space allowed for this type of drawer glide accommodates 1/2 inch on either side for a total of 1 full inch smaller width drawer compared to the cabinet opening. This is and always has been a tight specification. The original drawers were off by at least 1/4 inch or more.

View from the basement. Honestly I have no idea how the entire assembly of the kitchen cabinet drawers even stay in place going down the road. Boxes are screwed together with 3 drywall screws and sort of situated into these pockets made of 2-3 inch depth plywood. I have no idea how those pockets are held in place and it doesn't appear there is any support at the back of the cabinets as they set hovering over the wheel wells by perhaps half an inch. Would love to hear a more informed opinion about this. 

A few finished results installed. Some of you might see that instead of implementing 4 drawers at 4 inches I ended up building 4 inch on top, 5 inch in the middle, then the standard 6 inch for the bottom drawer. Increasing the middle 4 inch to 5 inch depth provides a bit better depth of space while still allowing plenty of adequate space between each drawer.