Creating cabinet drawer fronts and doors with laminated Birch plywood

[Big Taco]

What is the best process to create cabinet drawer fronts and doors using laminated Birch plywood? Edges will remain exposed.

Can I laminate an entire sheet of 4'x8' Birch plywood, edge the sides with a router, then use TS 55 to cut the drawer fronts and doors to the sizes I need or do I need to cut the plywood down to each individual  drawer front and door and then laminate each piece and route each edge?

Can I get a clean cut of laminated plywood using the TS 55? What blade would be recommended?

Thanks,

 

[nclemmons]

I'm not clear - you said in the first paragraph the edges would be exposed yet you are talking about edging them in the second one.  Not clear on your 'laminating' the plywood and what you mean there.

I'd personally rip a set to width from a 4x8 sheet for consistency and grain match and then cut to height for that 'cabinet section ' with each drawer or door wrapped with the edging if you choose to do that.  With baltic Birch, I find the edges can be left exposed for a great look.  I don't like non-Baltic edges exposed unless it's really good quality personally due to voids and color variations.  Then repeat with the adjacent drawers / doors to give you grain match in all directions.

Does this help with your question?

Post photos as you progress!  And welcome to FOG -

neil

 

[Big Taco]

Ok, thanks Neil.

Using Baltic Birch, so plan on leaving the edges exposed.

The question is, what is the most effective way to apply laminate (Formica) to plywood and cut to the size you need? Apply the laminate first to the entire sheet of plywood, then cut to sizes needed. OR cut plywood to sizes you need, then apply the laminate (Formica) to each piece?

Thanks,

 

[sparty]

I would advise against laminating first, and then cutting various components to size, unless you're using a saw with a scoring blade.

I like your idea of cutting the components to size, laminating them individually, and then finishing the edges with a router.

(I've never owned a TS 55 and so can't comment on its efficacy in cutting laminated ply. Maybe it's fantastic, in which case ignore my suggestion.  )

 

[Sparktrician]

Once you cut the door/drawer blanks to the correct size, laminate the ends (shortest dimensions) first, then flush-cut all four sides with a laminate trimmer using a bottom-bearing trimmer.  Then laminate the long sides, again flush-cutting the four sides with the laminate trimmer.  Now laminate the largest side and flush-cut all four sides.  Change the router bit to an Amana No-File bit.  Test your settings using a few practice pieces until you get the adjustment right.  Once you get the adjustment right, now go over all the edges exposed on the drawer fronts and doors to ease the sharp edges.  [smile]

 

[nclemmons]

thanks for the clarification.  I'd cut the doors / drawers first and then laminate and flush trim.  Much cleaner install with less chance of damage or chipping.

If you are interested, here's a thread on Garage Journal by [member=27782]Scorpion[/member] here on the FOG that you might find of interest.  He has organization and building down to a science!  I linked to his section on drawer fronts and laminate, but the entire thread is amazing if you are into organization...  in his case tools, but the ideas go well beyond that!

https://www.garagejournal.com/forum/showpost.php?p=7611449&postcount=807

 

[jjowen]

I am not advocating one way over the other, but I got the sheets of baltic birch ply laminated by the retailer. I then, with a bit of practice, was able to get really good edges with the TS 55 and the laminate blade (Festool 496309). Just say'n.

[attachimg=1]

 

[Mettes]

I am not advocating one way over the other, but I got the sheets of baltic birch ply laminated by the retailer. I then, with a bit of practice, was able to get really good edges with the TS 55 and the laminate blade (Festool 496309). Just say'n.

[attachimg=1]

I second this.  I do this a lot, always have my sheets laminated by my supplier.  Cut to size on my panelsaw or using the TS 55.  I then roundover/chamfer all the edges with a router, the Bosch cordless edgerouter is really the perfect tool for this.  Not much, maybe 0.5mm, just enough to take the edge of, and it hides all the possible little chip out you may have after cutting.  The little chamfer also makes chipping afterwords much less likely.

https://www.atelierh.be/vanhoovels