How Your Custom Cabinets are Made

Custom Cabinets are basically just wooden boxes with doors, drawers, and trim attached. What makes Texas Wood Mill’s cabinets different from the rest is the quality of workmanship and the attention to detail that helps insure your cabinets will continue to serve you for many years to come. After you have approved the design of your new cabinets, our design staff generates detailed drawings and parts lists for each part of your cabinets. Nothing is left to chance, everything is detailed out.

The first step in building the Cabinet Boxes is to have them cut out.  Practically all the plywood for the boxes is precision cut on our KomoBrand computerized (CNC) router.  In one process the parts are cut perfectly square with precisely spaced holes for adjustable shelves and perfectly placed dados for shelves, brackets, and supports.

While the plywood parts are being cut, Face Frames (the frames to which the doors are attached) are being built in a different part of the plant.  Hardwood lumber is ripped and planed to insure all the frame pieces are the correct width.  Pieces are then cut to length using digital measuring devices that are accurate to with 1/32nd of an inch.  Pocket screw holes are machined into each piece so the frames pieces can then be glued and screwed together.  Finally, the frames are sanded in our 43” wide belt sander creating a perfectly flat, finely sanded frame.

Drawers are cut out of high quality 9-ply plywood. Our computerized (CNC) router cuts the plywood to size, cuts the drawer bottom dado, the end mortise/tenon joint, and drills holes for the Drawer Front screws all at the same time.  If you have requested Dovetail joints on your drawers, the joints are machined on a special machine that makes the joint on both adjacent corner at the same time.  After being sanded and sorted, the parts are sent to our Drawer department where they are glued and nailed together.  The drawer boxes are placed in a specially designed jig where the drawer fronts are attached and the bottoms are inserted, insuring a perfectly square drawer.

Like face-frames, Cabinet Doors begin as raw hardwood lumber which is ripped to width and cut to length using a special digital measuring device.  Extra deep cope and stick joints are machined into the stiles and rails, each on dedicated shapers using specially designed insert shaper cutters to insure clean-smooth joints.  These extra deep joints provide more shear strength to the glued corners of the doors.  To reduce warpage, the lumber from which the center panels are made is ripped into 3”-4” wide strips that are then glued back together to avoid stress within the panel.  Once all the parts are ready, the doors are assembled on a dedicated pneumatic clamping device then run through our 43” wide belt sander.  The belt sander not only smoothes up the surfaces, it makes the doors perfectly flat.  After putting the desired edge on the door and drilling for hinges, the doors are hand sanded then checked for squareness and accuracy.

Once all the parts are ready, the cabinets are assembled.  The boxes are nailed together, frames attached, and all special mouldings and toe pieces put in place.  We use a liberal amount of glue to ensure the parts do not work themselves apart.  Once all the joints are smoothed and sanded, we attached the drawers, pull-outs, and any other specific hardware or accessory you have requested.  Once everything is sanded and has passed our quality control check, the finished cabinets are carefully loaded into our rain-tight trailers, ready to be delivered and installed in your new home!