Cutting a lightweight board cleanly and building a straight cabinet body from it is not rocket science. However, there are a few basics to keep in mind when cutting – especially if multiple components need to fit together perfectly later on.
In the first episode of our new epicPLY workshop series, we are not going to start by building complicated furniture. We are starting with the basics: we dimension a board, create a right-angled reference, cut the individual components, and build a simple cabinet body from them.
The cabinet body will later become part of our new work surface. At the same time, we can use it to demonstrate several work steps that are also frequently required in camper and furniture construction.
Our new epicPLY workshop
We want to transform a previously empty garage into a proper workshop, step by step.
In doing so, we don't just want to show the final result. Setting up the workshop gives us the opportunity to demonstrate various materials, tools, and processing techniques directly in real projects.
We are starting with a simple cabinet body for our future work surface.
For the material, we are using our Performance Multilayer made of European poplar. It is somewhat heavier than our Albasia boards, for example, but it has a more robust surface – an interesting property for use in a workshop.
What tools are needed to cut boards?
For our cutting, we use a plunge saw with a guide rail.
However, this is not the only option. Depending on the project and the available tools, boards can also be cut with other suitable saws, for example.
The most important thing is a clean and controlled cut.
For the plunge saw, we use a sharp saw blade with an appropriate number of teeth. We also work with a dust extraction system.
Anyone who only builds a project occasionally does not necessarily need to purchase a complete workshop setup. Tools can be rented, for example.
And if you don't want to cut your boards yourself at all, you can plan the required components directly via our epicPLY cut-to-size configurator and order them to measure.
→ Go to the cut-to-size configurator
Why should a board be squared before cutting?
An important point is often overlooked when cutting your first board:
The outer edge of a delivered board should not automatically be used as an exact reference for furniture construction.
With our boards, there is also about 1 cm of transport allowance around the actual usable dimensions. We do not charge for this area, and it serves, among other things, to keep potential damage to the outer edges during transport away from the actual usable dimensions.
Before we cut our individual components, we therefore first create a clean reference.
To do this, we first cleanly cut off one long outer edge.
Subsequently, we create a right-angled second edge to it. This gives us a defined 90° angle from which we can transfer our other dimensions.
This step is particularly important when building a cabinet body. Even small angular errors can compound over several components and become noticeable later during assembly.
Setting the sacrificial board and cutting depth correctly
When cutting, we place our board on a sacrificial board.
We set the plunge saw so that the saw blade only penetrates about 1–2 mm deeper than the board being cut.
This way, the backing is only slightly cut, and the board rests fully flat while being sawed.
Depending on the material, cut edges can be very sharp. This is especially true for coated boards. Consequently, one should work carefully when handling the freshly cut components.
Cutting several identical components
For a cabinet body, we need several components whose dimensions should match as accurately as possible.
It is not just the absolute measurement that is decisive here. It is particularly important that, for example, opposite sides or the base and lid are identical to each other.
For repeatable cuts, we use stops on our guide rail. This allows us to transfer the same measurement to several components without having to measure every cut completely from scratch.
Such stops are practical, but not a must.
Alternatively, the desired measurement can be marked in the classic way and the guide rail can then be aligned accordingly.
Plan the cut beforehand
Before the first parts are cut from the board, a cutting plan is worth it.
This allows you to think beforehand about how the required components can be arranged on a board as efficiently as possible.
You can also use our cut-to-size configurator for this. It allows you to plan the board requirements for a project – even if you want to cut the board yourself afterward.
This can help, especially with larger projects with many different components, to save material and unnecessary offcuts.
Processing cut edges
After cutting, the resulting edges can be finished.
A simple possibility is to lightly sand or bevel the sharp edge.
Alternatively, a router can be used, for example.
With our Performance Multilayer, the multi-layer construction and the dark glue create a visible multiplex edge. Depending on the desired look, the edge can therefore also be intentionally left visible.
When sanding, attention should be paid to the dust generated, and suitable respiratory protection should be used.
Screwing lightweight boards into a cabinet body
For our first workshop cabinet body, we deliberately use a very simple connection:
The boards are butt-joined and screwed together.
With suitable multiplex boards, screwing into the edge of the board is possible. However, it is important to pre-drill cleanly.
We first mark the position of the board. For a 15 mm thick board, the center is approximately at 7–7.5 mm.
Subsequently, the screw positions are marked and pre-drilled.
Pre-drilling reduces the risk of the material splitting when the screw is driven in. In addition, we countersink the holes so that the screw heads sit neatly in the surface.
When screwing, you should also work with a light touch. Poplar is a relatively soft wood – therefore, the screws do not need to be tightened with maximum torque.
Does a cabinet body always have to be screwed?
No.
Simple screwing is only one possible connection method and is an uncomplicated solution for our workshop cabinet body.
Depending on the piece of furniture, the desired look, and the available equipment, other connection techniques are also possible.
These are precisely the topics we want to cover bit by bit in the coming episodes of our workshop series.
Cut boards yourself or order them cut?
Both have their justification.
Those who like to build themselves and have the appropriate tools can achieve very precise results with a guide rail and a plunge saw. In addition, you are flexible during construction and can still adjust dimensions during the project.
Conversely, those who want to start with the actual furniture construction as quickly as possible or do not have the appropriate tools can have the required components cut directly.
At epicPLY, you can plan and order your components via our cut-to-size configurator.
The first building block of our new workshop
With the first cabinet body, the beginning of our new workshop setup is now in place.
In the next episodes, we will continue to expand the workshop step by step and use the individual projects at the same time to show different processing techniques.
This is not just about our workshop. Many of the work steps shown can be just as easily applied to camper van conversions and furniture construction with lightweight boards.
Which processing technique should we take a closer look at next?
Feel free to post your questions under the YouTube video. We will address frequently asked questions in future videos and posts.
