This project was built and designed by Marcus from Salty Woodworking. It takes a full sheet of birch plywood and turns it into a set of custom cabinets that look great and function even better.
Although the project took longer than expected, it became a valuable learning experience. The result is a set of clean, modern cabinets that show how steady effort and simple tools can lead to impressive results.
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Starting with the Plywood
Marcus begins by breaking down a large sheet of birch plywood using a track saw. This tool makes handling full sheets far more manageable, especially when working solo.
Since the cabinets don’t include a full back panel, narrow strips of plywood are cut to help stabilize the frame. These strips also keep the overall structure square during assembly.
Assembling the Cabinet Boxes
The carcasses are joined using pocket hole joinery, which allows the screws to stay hidden from view. A pocket hole jig speeds up the process and keeps the angles consistent.
Screws are added gradually to secure each piece while keeping everything aligned. Once the first few joints are tightened, the boxes quickly start to come together.
To fit the cabinets in place, toe kicks are added to the bottom. A multi-tool makes quick work of removing the baseboard so the new cabinets can sit flush.
Once the toe kicks are in, the carcasses are moved upstairs for easier final assembly. Working in the space they’ll eventually occupy helps fine-tune the fit.
Building the Face Frames
For the face frames, Marcus uses 1×6 poplar boards that are dimensioned for a clean, consistent appearance. Each piece is cut to length, then joined with wood glue and brad nails.
After assembly, any gaps are filled with wood filler. This step ensures the frames look seamless once finished and painted.
Making the Doors
Door parts are also made from poplar, cut into stiles and rails with a groove for a plywood center panel. Each panel is dry-fitted before gluing to check for a snug fit.
Once glued, the doors are clamped overnight. This gives them time to cure fully, resulting in strong, square doors ready for sanding.
Smoothing and Finishing
Seams and minor imperfections are filled before sanding begins. The doors are sanded thoroughly to ensure a smooth finish ahead of painting.
A cabinet hinge jig makes drilling for hinges faster and more accurate. Marcus runs into a small issue where the doors were cut slightly too wide, but a few adjustments solve the problem.
Creating the Tops
For the cabinet tops, hard maple is selected to match existing furniture. Each board is planed and jointed before being glued up.
A template is made to shape the final fit. After rough trimming, the tops are sanded smooth and prepped for finish.
Final Finishing and Installation
Rubio Monocoat is applied for a natural, durable finish that brings out the wood’s character. A DA polisher is used to achieve an even sheen.
Once cured, the tops are installed and the cabinets are set into place. The finished result is clean, practical, and built to last.
Final Thoughts
This project highlights how patience and attention to detail can result in beautiful, functional furniture. Mistakes along the way become lessons that build confidence for future projects.
Marcus from Salty Woodworking shares every step of the process in his video, offering helpful insights along the way. It’s a rewarding build for anyone looking to grow their skills and create something truly custom.
Please support Marcus by visiting his website: https://www.saltywoodworking.net/.
Matt’s Take
These are my personal thoughts and tips based on my own experience in the shop. This section is not written, reviewed, or endorsed by the original creator of this project.
What strikes me about this build is how Marcus tackled a full cabinet project with straightforward tools and techniques. That track saw approach for breaking down plywood is spot-on — trying to wrangle a full sheet through a table saw solo is asking for trouble, both safety-wise and accuracy-wise. The pocket hole joinery keeps things simple while delivering clean results that’ll hold up over time.
The decision to use poplar for the face frames and doors makes a lot of sense for a painted finish. It’s stable, takes paint beautifully, and won’t break the bank like hardwood would. That wood filler step is crucial too — poplar can be a bit soft and prone to minor dings during assembly, so taking time to fill and sand ensures everything looks crisp once the paint goes on.
I really appreciate the hard maple choice for the tops. Having that natural wood contrast against painted cabinets adds visual interest and gives you a durable work surface. Rubio Monocoat is solid for this application — it’s user-friendly and gives you that protective finish without looking plastic. The whole approach here shows that custom doesn’t have to mean complicated.