It depends on the corner cabinet you are building. I always start with the deck and side panels, attach the sides to the deck, then insert the back, followed by the tops, nailers, and any additional parts from the order. This sequence allows you to move the cabinet around more easily while assembling. Even the more complex corner cabinets are built using this same general method.

One of the advantages of the 3 4 inch thick plywood used in the City line is its rigidity and strength. The dense core allows parts to be fastened together securely without worrying about screws pulling out of the material. This also allows for slightly more aggressive handling during assembly compared to many RTA cabinets that use lower quality plywood cores.

We have received a few customer reports that the deck slots appear slightly misaligned at the deck. I reviewed current in house parts and did not find anything that mirrors the reported issues. Our best assessment is that a dull CNC blade is the cause. The blade makes multiple passes across the dado to open the slot wide enough to accept the back panel. On smaller width cabinets, the deck is narrow and often only allows for a single clamp to hold it in place during machining. This limited hold down, combined with the extreme density of the plywood core, makes the cut more difficult for even a slightly dull blade.

To prevent this from happening going forward, we are implementing several changes. First, we will increase the slot width by 1 millimeter to provide more tolerance during assembly. Second, we will reduce the dado depth and the plunge depth into the tops and bottoms. This will prevent the blade from cutting too deeply into the plywood and reduce the chance of the part shifting in the clamps. This issue appears to be isolated to the City cabinet line due to the denser and heavier plywood core.