Batch run — 80 cabinet doors

The dining hall had eighty matching base cabinets that needed new fronts in birch ply with a Euro-style 35 mm hinge cup and an integrated finger pull. The kibbutz wanted them in three weeks — which on an 80-piece batch means production has to be right the first time.

We nested the doors with a single fixturing setup so every part referenced the same datum corner. The 35 mm hinge cups were drilled in the same nest, which meant zero variation in cup depth across the batch — critical because eighty mismatched doors at install would have meant eighty hand-shimmed hinges.

The finger pulls are a 12 mm radius router pocket along the top edge, 60 mm deep. We rough-cut with a 10 mm bit and finished with a 6 mm bit at a slow feed for a clean edge that does not snag when the door swings open.

Edge banding was done in-house on an automatic edge bander, then sanded to 240 grit. The doors shipped on three pallets and the install crew put all eighty up in two days.