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How to cut a base end panel?

We are using kitchen cabinets to create office storage. Due to the particular requirements, we need to cut the end panel that will go on a base cabinet. The end panel is in white gloss. Any advice on how to cut this without leaving a blemish?

Thanks in advance

Mary

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EricL

Hello @MaryBird

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your question about cutting a base end panel.

If you are using a Kaboodle base end panel in gloss white, please note that cutting it could cause the vacum laminated sheet to peel and tear off. If you still wish to proceed, I suggest putting masking tape on the cutting line to prevent the laminate from chipping and lifting. Make sure that the side that will be seen from the outside is facing towards the bottom. Quite often the blade damages the finish on the top as it is being hit by the cutting edge of the blade.

Once the panel has been cut and the laminate starts to lift off the surface, I suggest using Selleys 500ml Kwik Grip Horizontal Contact Adhesive between the laminate and MDF board. Please make sure to allow the adhesive to cure before you install the panel. My only other suggestion is to use a high-count fine-tooth blade on your saw for a clean cut.

Let me call on our experienced members @Dave-1 and @Nailbag for their recommendations.

If you need further assistance, please let us know.

Eric

Dave-1

Good Evening @MaryBird

I havnt cut a Kaboodle high gloss panel but have cut a grey ex work laminated bookcase panel. I used my makita drop saw (still with the standard blade that it came with so not sure of the tooth count) but just took my time sliding the blade through the material. I actually faced the cut with timber trim and 40mm bullet head nails. There was no splintering of the laminate (thought there could be)

Only suggstion id add would be to but down some painters tape strips along the cut so the surface isnt scratched by chance. For the Part that you are going to trim off, why not do I shorter trim first to get a feel for the cutting? Costs nothing and may give you an idea if there is an issue.

Dave

Nailbag

Hi @MaryBird

I have performed these cuts many times on Kaboodle panels.

1. Lay the board upside down on saw horses or similar with the face on the side you're starting your cut from. Ensure the end to be cut off is supported near the cut and clamp it.

2. Measure and mark your cut line.

3. You will now either need to setup a fence on your circular saw, or setup a cutting guide like the photos. This was a door being trimmed down but the process is the same.

4. You will need a circular saw blade of 40 tooth or greater.

5. With the power disconnected, adjust the saw's height so the blade is about 5mm deeper than the thickness of the panel. So about 25mm deep.

6. Wear a dust mask and eyewear as the cut causes a lot of fine MDF dust.

7. Position your saw ensuring the blade isn't touching the panel, and slowly make the cut. Slow down towards the end. If it's a large offset, have someone support it carefully so it remains flat and doesn't pinch the blade during the cut. And remember to perform the cut so the line is just left on the good side.

You should be left with a very fine clean cut.

Nailbag.

MitchellMc

Hi @MaryBird,

As @EricL mentioned I too have concerns about the vacuum-formed coating. Unlike laminate, which is a solid veneer of plastic with is adhered with glue, kaboodle panels have a vacuum-formed coating. It's like a large white plastic bag that is applied to the underlying panel through a vacuum sealing process. If you cut the end off the panel the coating can retract exposing the underlying board.

You might like to consider speaking with our helpful team at your local store's Special Orders counter. They'll be able to check with Kaboodle as to whether we can order you a custom end panel to suit.

Please let me know if you have any questions.

Mitchell

MaryBird

Thanks for your reply and suggestions.

We did a test cut to discover which way to lay the panel. The tape is a good idea too.

We did this with a table saw and it worked well.

Regards