After all of our planning it was time to get building. First up, the bottom portion.
We made a cut list based on my drawings and cut everything down to size. We planned to use a combination of MDF, cabinet grade plywood and poplar. In the end, everything would be color matched to their baseboards and painted. After we cut everything down we got to work.
We took the pieces of MDF we cut for the sides of the cabinet and used an awesome jig Chris got for drilling out our adjustable shelving holes
The jig made things super easy and after about 15 minutes we were done with both pieces
With the adjustable shelving holes drilled, we started assembling
We attached the bottom fixed shelf to the structure using wood glue and clamps (we didn't want any nails visible)
For the top "counter" we attached it using pin nails towards the back where the top cabinet will cover it, then Chris used the kreg jig to attach the counter towards the front on the sides so no joining method would be visible on the top
With the counter attached we nailed in some poplar for the counter trim to attach to (it's thicker than the counter)
With the base mostly complete, Chris started assembling the adjustable shelves. The main part of the shelf would be plywood, and the attached face frame would be poplar. Again, Chris used a kreg jig so that no joining of the two pieces would be visible
Once the first shelf was made we put it inside to make sure the sizing was correct (and you can see that the counter trim was attached as well)
I think it looks pretty damn good!
(and remember there will be fluted trim on the sides)
We made 3 adjustable shelves. I think the space is really only big enough for two without it looking too crowded, but you'd always rather have too many shelves than not enough.
Once the bottom cabinet was finished, it was time to work on the upper one. First, we cut out the arch for the top. We weren't really super sure how to get a good, symmetrical curve, but Chris came up with a good idea to use some scrap masonite
The first tracing was a bit off
But after we finally got it right (I think it took us 3 tries) we got the jigsaw and Chris cut it out
Then we sanded it all down to smooth things out
Afterwards we had some concerns about how all the trim (the arch, the fluting, the crown) were going to match up with each other at the top
Things weren't really lining up in a way that we were satisfied with, so we pondered some ideas. We came up with adding a piece of coved trim between the crown and arch to remedy the height differential
Then it was time to build again. We used the adjustable shelf jig again and started assembling (very handsome Chris)
Unfortunately at this point I started more patio digging, so I didn't get any more upper cabinet progress pics until Chris was done
How sharp does that look?
With both cabinets built and the trim all cut down and sanded we set about getting things primed. Chris taped off the edges of the cabinet so that once we attached the trim the adhesion would be a bit stronger
Then it was paint paint paint paint paint paint. Everything - the upper and lower cabinets, all the trim, and all the bottom shelves (the top shelves will be glass) - got 2 coats of primer with a sanding between coats
With everything primed...
...a few days later we sanded it all down again
My parents went with Kelly Moore paint (they've used it everywhere else in the house). Chris was excited to try a new product of their's called 1930 water-oil hybrid
It has the great durability and hardness from an oil-based, but the simplicity and easy clean up of a water-based, so using the sprayer to paint it on wouldn't involve clean up with mineral spirits (which would have sucked the big one)
We sprayed everything with 2 coats of paint and it only used maybe 2/3rds of a gallon which is awesome because that cabinet is a behemoth (about 4 ft. wide and 7 ft. tall) and that paint is expensive (it clocked in at just over $50 with tax for 1 gallon, yikes).
And once paint and clean up was done, we were ready for install!
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