Galley Kit Install
 

Step 1-

All Drawer and Cabinet Doors need to be removed from their hinges. Mark each item with a piece of masking tape indicating their original location and its UP orientation. This is important in the next step for determining the grain selection and direction.

Hints:

1) Use a battery screw/drill to remove the screws. There are a lots of them and the screws differ based on the surface they go into. Use different plastic drinking cups to separate the screws

Step 2-

Lay all the drawer faces and the cabinet doors face up on the .020 Nuvacor laminate. Look at the UP orientation you marked on the back of the drawer face/cabinet door and match up the grain orientation you want with it. Once you are satisfied with the orientation of all the pieces, outline them on the surface with a permanent marker.

Hints:

1) GRAIN ORIENTATION is extremely important. Most boat builders use a vertical orientation for the grain as depicted on the picture to the left. The grain orientation applies to the cabinet frames as well.

When using a light or dark burl, grain orientation is less important.

Step 3-

The picture to the left shows the technique described in Step 2.

Cut out each piece with a large pair of sharp cutting scissors.

Step 4-

Prior to installing the new laminate, make sure the old laminate surface is clear of imperfections. Any imperfections will show up in the new laminates high gloss surface.

Hints:

1) Your hand is the best tool to determine imperfections on the surface. Use Windex to clean the surface and let it dry.

Step 5-

Peel back about 1.5" to 2" of the wax paper protecting the adhesive.

Step 6-

Lay the laminate on one of the drawer faces/cabinet doors making sure the grain orientation matches the orientation marked on the back of the drawer face/cabinet door. Align the laminate making sure that enough material overlaps all edges by at least 1/8".

Hints:

1) Proper coverage is far more critical than perfect alignment. A laminate askew is a home run compared to one that does not cover the entire surface and must be removed.

Step 7-

When everything is ready, press down along the uncovered edge. Work slowly, reaching under and pulling back another 2". Press down along the uncovered edge and repeat.

Hints:

1) What you are trying to avoid is to getting a bubble trapped between the laminate and the surface. By working slowly you will avoid this.

Step 8-

Continue working left to right (if you are right handed) a glove also helps to apply pressure up and down on the laminate. Continue to remove the wax paper 2" at a time and apply pressure to the exposed adhesive.

Step 9-

Roll the entire surface with a "J" roller applying pressure on the entire laminate surface.

Step 10-

When the all the drawer faces and cabinet doors are complete they are ready for the router. Use a flush cut bit and follow up with a 45 degree bit to finish the cut and then sand the edge with a 120 grit belt on the belt sander.

Once the edge work is complete, carefully drill all the door/drawer pull handle holes.

Finish the wood edges with stain/polyurethane to match.

Hints:

1) Use a routing table for this work. The pieces are too small to run a router around consistently.

Step 11-

All the practice on the smaller pieces comes into play on the cabinet faces. The same principals apply. In the photo on the left, this type of installation between two existing pieces of molding is very difficult to get perfect. A better way is to remove the molding at the top and bottom prior to installing the laminate. Once the laminate has been secured and routed, the molding can be reinstalled.

Step 12-

Once the laminate is installed, it is ready for the router. Use a razor knife to cut a hole in the laminate to insert the flush cut router bit. Follow up with the 45 degree bit adjusting for the proper beveled edge.

Hints:

1) Use a small laminate router to cut the holes out.

2) The router will blast material everywhere. Make sure you have proper eye, ear and breathing protection.

3) Notice that if you must join two pieces, the technique to do so is over an opening (in this case the drawers below the sink) which significantly reduces the length and visibility of the join.

Step 13-

Remove the grain protective sheet, install the door handles and admire your work!

 
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