Garage Cabinets

[arrdvarrk]

I acquired a number of 3/4" panels with a particle board core and laminate/formica on both sides.  My thoughts are to cut the 4'X8' panels to make some cabinets for my garage.  From the pictures you can see that the laminate on one side is a Festool green color and the laminate on the opposite side is a dark wood grain pattern.  My first question is what TS55 blade would be best to use to cut these panels down to size?  Would Festool's Solid Surface / Laminate 48-Tooth Saw Blade - 496309 be best?

[attachimg=3][attachimg=1][attachimg=2]

What would be the best method to join the sides and top/bottom of the cabinets together?  Would dominoes be sufficient and how hard would the laminate be on the domino cutter?  Would a rabbet with glue and screws be better?

I appreciate any suggestions anyone has.

 

[cblanton42]

I've used that blade and yes you have the correct one for the job.  As far as connecting the panels I can tell you what WON'T work from experience, screws into the particle board.  I tried some Kreg pocket screws in this exact situation and they did not hold at all so I'm sure the domino would be "better" but I've never used it for this exact application so others may need to chime in here.   

 

[eddomak]

I've used that blade and yes you have the correct one for the job.  As far as connecting the panels I can tell you what WON'T work from experience, screws into the particle board.  I tried some Kreg pocket screws in this exact situation and they did not hold at all so I'm sure the domino would be "better" but I've never used it for this exact application so others may need to chime in here. 

I used 5x30 Dominoes with 12/20 mortises (as 15/15 would risk blowing out the laminate) for strength and alignment on weaker material (melamine covered particleboard), and Kreg pocket screws for clamping and backup. It was definitely strong enough (photos in my "Members Projects" thread here. It actually supports my 65kg hanging off (so I wasn't concerned my kids would break it).

I also used dominoes only on some smaller pieces (CD storarge boxes) that were covered in Formica (maybe I will update my original thread with the final pictures tonight) with no problems about the domino bit getting through at all.

 

[AlexThePalex]

That solid surface/laminate blade is indeed the correct one.

Unlike in North America, particle board is widely used here because it is cheaper than solid wood. With factory cabinets it is often glued and doweled, but you can also screw it, when you use the right screws.

Particle board screws is a whole category of screws here and widely available in many different sizes. They generally have a thin core, a wide head and a wide but very sharp thread. If you don't pay attention you can cut your fingers with the thread. A thin pilot hole is recommended, but not always necessary.

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Whether you use dowels/dominos or screws, you should place more of them and closer together than you are used to with solid wood. Particle board is not as strong so you have to divide the load.

 

[Picktool]

Alex, those are Spax screws right? First time I used
those ... err yes very sharp  [embarassed]

 

[AlexThePalex]

Alex, those are Spax screws right? First time I used
those ... err yes very sharp  [embarassed]

Yes, very sharp, been there.  [smile] Spax makes them, but many other companies too. Picture is just an example, they don't all look exactly the same.

 

[sancho57]

You could use confidant screws and they do make a melamine glue.

So I would domino then glue and screw.

 

[abgoto]

That is 20mm melamine.  Even with dust collection, I recommend using a respirator as there will be very fine particles of some nasty stuff in the air when cutting it.

Glue and dominos will provide a strong joint.  If you use a butt joint, trim off the laminate by skimming the surfaces to be joined with a router.  Use 5x30mm dominos with a 15mm mortise on each piece.  Alternately, cut each edge to be joined on a 45.  If you go this route, you will need to trim about 3mm from each domino and reduce the mortise depth to 12mm.

 

[arrdvarrk]

Thanks for all the help everyone.  Much appreciated.

 

[sae]

I've used that blade and yes you have the correct one for the job.  As far as connecting the panels I can tell you what WON'T work from experience, screws into the particle board.  I tried some Kreg pocket screws in this exact situation and they did not hold at all so I'm sure the domino would be "better" but I've never used it for this exact application so others may need to chime in here. 

Were you using the coarse Kreg screws?

I've used the coarse ones in some very questionable particle board and it holds together fine. Don't expect it to take the load of solid wood, but I'd expect the thing to bow before the screws pull out.

 

[cblanton42]

I've used that blade and yes you have the correct one for the job.  As far as connecting the panels I can tell you what WON'T work from experience, screws into the particle board.  I tried some Kreg pocket screws in this exact situation and they did not hold at all so I'm sure the domino would be "better" but I've never used it for this exact application so others may need to chime in here. 

Were you using the coarse Kreg screws?  Yes but they would not hold for me at all, just crumbled the particle board as soon as it began to tighten up.  Even tried one by hand and still stripped out, it's possible I had poor quality particle board I guess but didn't seem any different than normal.  I've used the coarse ones in some very questionable particle board and it holds together fine. Don't expect it to take the load of solid wood, but I'd expect the thing to bow before the screws pull out.