I'm currently working on a toolbox hutch with my brother. We've built the box, using 3/4" maple plywood for the sides and 1/2" for the roof. The problem I'm facing is with the door mechanism. I bought flipper pocket door slides, but the door, being made from 3/4" plywood, is too heavy for those slides. I'm wondering if there's a way to use gas struts with a flipper pocket design for the hutch door. Any suggestions?
3 Answers
Have you thought about making a thinner door? It seems like a practical solution regardless of how you decide to open it. You could even use two doors instead of one. Another idea could be to use dowels as hinge pins and cut grooves in the walls for the door to pivot and slide back. Just a thought!
I get what you're saying about the door being heavy. If you want to keep it open at times without it sliding into the cabinet, maybe reconsider the pocket mechanism altogether. Not all slides are made for horizontal doors; they often work better for vertical ones. Look into higher quality hardware from brands like Rev-A-Shelf or Blum. They might have more suitable options.
I understand your frustration. You might want to check the weight specifications of your current slides and see if they're rated for heavier doors or just for lighter ones. Sometimes, upgrading to more robust hardware can make a big difference. Also, I'd be curious to see how your design develops—I love a good DIY project!