Case studies give homeowners something that product comparisons and specification guides cannot, a real look at how a custom cabinetry project unfolds in practice. This post walks through a completed cabinetry project by D.E. Mitchell Construction in New Bern NC. It covers the starting conditions, the design decisions, the production process, the installation, and what the homeowners got when everything was complete.
Project Overview
Location: New Bern, NC Home type: Single-family, 2000s construction Project scope: Full kitchen cabinet replacement plus home office built-in and primary bathroom vanity Cabinet material: Painted maple, plywood box construction throughout Door style: Shaker throughout, painted white in kitchen and office, painted navy in primary bathroom vanity Countertops: White quartz in kitchen, white quartz in primary bathroom (separate countertop project coordinated by D.E. Mitchell) Hardware: Matte black pulls throughout all three spaces Production timeline: Six weeks from design finalization to delivery Installation timeline: Eight days across all three project areas Total cabinetry project cost: $68,000 installed across all three spaces
The Starting Conditions & the Client’s Goals
The homeowners, a couple in their mid-40s with two teenagers, had lived in the home for six years. The kitchen cabinets were original to the home’s 2002 construction, builder-grade particleboard boxes with thermofoil door faces. Over six years of regular family use, the thermofoil had delaminated on three doors adjacent to the dishwasher and on the door immediately to the right of the range. The box bases under the sink and adjacent to the dishwasher had minor swelling at the front edges. The interior configuration, standard fixed shelves throughout, no drawer stacks, was a consistent source of frustration for a household that cooks frequently and actively.
The home office, a dedicated room off the main hallway, had no built-in storage. The homeowners had been using freestanding bookshelves and a freestanding desk for six years and wanted a built-in solution that used the room’s wall space fully and created a workspace that felt intentional rather than assembled.
The primary bathroom vanity was the original builder-grade single vanity, 36 inches wide with a drop-in cultured marble sink. After remodeling the bathroom tile and shower two years earlier, the original vanity was the remaining element that had not been updated. The bathroom was used by both adults and the single vanity was a daily friction point.
The homeowners decided to address all three spaces in a single project. Coordinating a multi-space cabinetry project with one contractor eliminated the scheduling complexity of three separate projects and allowed hardware and finish decisions to be unified across all three spaces.
The Design Process
The design phase took three weeks and involved two site visits and one design review meeting.
First site visit, measurement & assessment. The project lead visited the home and took detailed measurements of all three spaces. The kitchen measurements captured every wall dimension, the height from countertop to ceiling, the position of every window and door opening, and the location of all plumbing, electrical, and gas connections. The home office measurements captured wall dimensions, door and window positions, ceiling height, and the location of the electrical outlets that would need to be accessible within the built-in. The primary bathroom measurements captured the available width and height for the vanity and the plumbing rough-in positions.
During the kitchen assessment, the project lead identified the delaminated thermofoil doors, tested the hinge mounting points throughout the kitchen, and checked the base panels under the sink and adjacent to the dishwasher. The assessment confirmed the box condition the homeowners had described, failing thermofoil, swelling at base panels, and hinge mounting points that were loose at three door locations. Full replacement was the appropriate scope.
Design development. Working from the measurements, the design team developed a full cabinet layout for the kitchen, every cabinet section sized to the exact wall dimensions, the interior configuration of each section specified based on the design meeting discussion, and the corner solution designed for the specific corner dimensions.
The kitchen design incorporated:
- Extended upper cabinets to the ceiling, the 2002 construction had 9-foot ceilings with a 6-inch soffit above the original upper cabinets. Eliminating the soffit and building upper cabinets to the full ceiling height added approximately 18 linear feet of storage volume and eliminated a dated design element.
- Deep drawer stacks in five base cabinet sections, adjacent to the range on both sides, in the island base on the cooking side, and in the section adjacent to the main preparation area. Door-and-shelf configuration retained only in the base cabinets under the sink and for one base section used for large infrequently used items.
- Pull-out shelf systems in two remaining base cabinet sections with door-and-shelf configuration.
- A pull-out trash and recycling cabinet built into the base run adjacent to the sink.
- An extended island, the original kitchen had a freestanding island that was removed. The new custom island was built to the exact footprint available, with a deep drawer stack on the cooking side and open shelving with a bottom cabinet on the seating side.
- An appliance garage at the end of one upper cabinet run, sized for the household’s coffee maker and toaster, with an electrical outlet inside.
The home office built-in was designed as a full wall installation, floor to ceiling across the full 14-foot wall width. The design incorporated:
- A central desk section at standard 30-inch desk height with a knee space opening and a drawer stack on the right side
- Upper bookshelves above the desk section with adjustable shelves at the household’s specified heights
- Base cabinet sections flanking the desk on both sides for closed storage
- Open shelving above the base cabinets on both sides of the desk
- A full-height upper cabinet section at the right end of the wall for closed storage of office supplies and equipment
The primary bathroom vanity was designed as a 60-inch double vanity, the maximum width the bathroom could accommodate between the toilet and the tub alcove, in a painted navy finish with matte black hardware. Two undermount sinks with deck-mounted faucets. Three drawers per side with a center door section for plumbing access.
Design review meeting. The homeowners reviewed the full design package, cabinet layout drawings for all three spaces, hardware specifications, finish specifications, and interior configuration documentation. Two changes were made during the review:
Change 1, Island seating side configuration. The original design had closed cabinet storage on the seating side of the island. The homeowners changed this to open shelving on the seating side for a more accessible and visually open configuration for the items they planned to store there.
Change 2, Home office desk height. The husband, who would be the primary desk user, is 6 feet 3 inches tall. Standard desk height at 30 inches was confirmed to be appropriate after the homeowner tested the height at an existing desk in the home during the review meeting.
The design was finalized and the contract was signed at the end of the design review meeting.
Material Selections
All material selections were finalized at contract signing and documented in the specification sheet.
Box construction: 3/4-inch birch plywood throughout all three spaces. 1/4-inch plywood backs dadoed into box sides.
Door & drawer face material: Solid maple throughout, the tight grain of maple was specified for painted applications to minimize grain telegraphing through paint.
Door style: Shaker throughout all three spaces. The consistent door style across kitchen, office, and bathroom created a visual connection between the three spaces that the homeowners specifically wanted.
Finish:
- Kitchen and home office: Benjamin Moore Chantilly Lace, satin sheen, conversion varnish topcoat
- Primary bathroom vanity: Benjamin Moore Hale Navy, satin sheen, conversion varnish topcoat
Hardware: Matte black bar pulls throughout, a consistent pull profile in two sizes (96mm for door pulls, 128mm for drawer pulls) across all three spaces.
Countertops: White quartz with a polished finish. Kitchen countertops and primary bathroom vanity countertop specified with the same material for visual continuity.
Production
Production ran six weeks in the D.E. Mitchell shop. The production sequence was organized to allow installation in the kitchen first, enabling the kitchen to return to function before office and bathroom installations were completed.
Week 1, Material preparation. Birch plywood panels were cut to all required dimensions for box components across all three projects. Maple was milled and prepared for door and drawer face production. All cuts were made from the finalized design drawings with dimensions specific to the measurements taken during the site visit.
Week 2, Box assembly. Cabinet boxes were assembled for all three spaces. Dado cuts were routed into box sides for back panel insertion. Boxes were assembled with glue and mechanical fasteners at all joints. Face frames were applied to kitchen cabinets. All boxes were checked for square before proceeding to finish preparation.
Week 3, Door & drawer face production. Shaker door frames and center panels were assembled for all three spaces. Drawer fronts were sized and prepared. All door and drawer faces were sanded to final preparation for finishing.
Week 4, Finishing. All cabinet boxes and door faces were finish-prepared, any surface variation filled, sanded, and primed. First finish coat applied and cured. The kitchen and office components were finished in Chantilly Lace. The bathroom vanity components were finished in Hale Navy. Curing time was allowed between coats per the conversion varnish manufacturer’s specifications.
Week 5, Second finish coat & hardware preparation. Second finish coat applied to all components. Hardware mounting holes were drilled in all door and drawer faces before delivery. This eliminates the risk of drilling errors during installation and allows hardware installation to proceed efficiently on site.
Week 6, Quality inspection & delivery preparation. All components were reviewed under a raking light for surface quality. Any surface variation identified during inspection was addressed. Components were packaged for delivery to protect finished surfaces during transport.
Installation
Installation was completed in eight working days across two weeks.
Days 1 & 2, Kitchen demolition & preparation. Existing kitchen cabinets were removed and disposed of. During demolition, the project lead assessed the wall conditions and confirmed the soffit removal scope. The soffit above the original upper cabinets was removed, a non-structural element that was framed out during the original construction. Drywall was patched at the soffit removal area and prepared for cabinet installation.
The existing kitchen flooring extended under the original base cabinets. With the base cabinets removed, the original flooring was visible at the toe kick area, a different flooring material than the tile installed after the original cabinets. The project lead confirmed the approach for handling this transition with the homeowners before proceeding. A new toe kick at a consistent height from the finished floor surface addressed the transition cleanly.
Days 3 & 4, Kitchen upper cabinet installation. Upper cabinet installation began with the wall run that required the most precise fitting, the run adjacent to the window, where the cabinet had to be built around the window opening. Upper cabinets were installed level, secured to wall studs at the required fastening points, and confirmed plumb before proceeding. The ceiling-height cabinets required installation in two sections: a standard-height upper cabinet installed first, with an additional upper section installed above it and scribed to the ceiling to account for any ceiling variation.
Day 5, Kitchen base cabinet installation. Base cabinets were installed level on the kitchen floor, shimmed where needed for the floor’s minor variations, and secured to wall studs. Cabinet runs were confirmed square to each other at the corner. The pull-out trash and recycling unit was positioned and the door alignment was confirmed before the adjacent cabinets were secured.
Day 6, Island installation, hardware, & kitchen completion. The kitchen island was set in the planned position and confirmed level. Drawer stacks and open shelving on the seating side were confirmed operational. All kitchen drawer slides and hinges were adjusted for consistent gaps and smooth operation. Matte black hardware was installed on all kitchen doors and drawers. Under-cabinet lighting was installed at the base of the upper cabinets, the electrical rough-in had been completed by a licensed electrician before cabinet installation began.
Day 7, Home office built-in installation. The full-wall office built-in was installed in sequence, base cabinets first, then the desk surface, then upper sections. The installation required careful management of the sequencing to maintain access to the wall for fastening as each section was added. Electrical outlet access within the built-in was confirmed, cut-outs in the back panel at the appropriate locations allowed existing outlets to remain accessible from inside the open shelf sections. Hardware was installed and all doors and drawers were adjusted.
Day 8, Primary bathroom vanity installation & project completion. The 60-inch double vanity was installed in the bathroom and confirmed level. Plumbing connections for both sinks were made by a licensed plumber who was coordinated to be on site for this phase. Matte black faucets were installed and tested. The countertop templating was completed, the fabricator templated after vanity installation was confirmed level. Countertop fabrication lead time was ten business days, with countertop installation following Day 8 as a separate installation visit.
The Final Walkthrough
The homeowners and project lead walked all three spaces at the end of Day 8.
Kitchen punch list:
- One upper cabinet door needed a minor hinge adjustment; the door was not closing flush with the adjacent door. Adjusted on site.
- A paint touch-up was needed at the junction between the new drywall at the soffit removal area and the adjacent existing wall. The paint had been applied before cabinet installation and was scuffed during installation. Painted touch-up completed the same day.
Home office punch list:
- One drawer in the desk section did not have a consistent gap at the top of the drawer face, a 1/8-inch variation compared to the adjacent drawers. The drawer slide was adjusted and the gap was confirmed consistent.
Bathroom vanity punch list:
- No punch list items noted at the vanity itself. Countertop installation was confirmed scheduled for ten business days after the walkthrough.
All punch list items were resolved before end of business on the walkthrough day.
The Results
Kitchen. The extended upper cabinets to the ceiling eliminated a dated soffit and added storage volume that the household uses for seasonal serving pieces and infrequently used equipment, accessible with a step stool but not taking up prime space in the lower sections. The drawer stacks in five base cabinet sections changed how the kitchen functions for a family that cooks regularly, pots, pans, dry goods, and utensils are accessible without removing other items first. The island with open seating-side shelving provides a landing zone for items in transit that the household uses consistently. The hardware consistency across all cabinet sections produces a kitchen that looks intentional rather than assembled.
Home office. The full-wall built-in replaced six years of freestanding furniture with a fixed installation that uses the wall space fully and fits the room as if it was always there. The husband works from the office daily and noted in a follow-up conversation that the desk height, the drawer configuration, and the cable management within the built-in exceeded what he had expected from the design drawings.
Primary bathroom. The 60-inch double vanity in navy eliminated the single-vanity morning conflict that had been a daily frustration. The navy finish creates a distinct visual break from the white kitchen and office cabinetry while the consistent shaker door style and matte black hardware connect the spaces. The countertop installation, completed ten business days after the vanity installation, completed the bathroom update.
Total project cost: $68,000 installed across all three spaces, within the $64,000 to $72,000 budget range established at contract signing. No conditions were discovered during installation that affected the budget. The contingency reserve was not consumed.
What This Project Demonstrates
Multi-space cabinetry projects benefit from unified design. Coordinating the kitchen, office, and bathroom cabinetry as a single project allowed hardware and finish decisions to be unified across all three spaces. The result is a home where three distinct cabinet installations read as part of a coherent whole rather than three separate decisions made at different times.
Design investment before production prevents installation problems. The two-change design review, adjusting the island seating side and confirming the desk height, resolved both changes at a point where they cost nothing to implement. The same changes made after production began would have required rebuilt components. The design phase exists to make these decisions at the right time.
Extended upper cabinets to the ceiling are worth the scope. The soffit removal and extended upper cabinets added scope and some drywall work to the kitchen installation. The result, a kitchen with continuous cabinet faces from counter to ceiling and additional accessible storage, is one of the elements the homeowners specifically cited as the most noticed improvement in the finished space.
In-house production & installation by the same team eliminates fit errors. The team that built the cabinets installed them. The measurements taken during the site visit were the measurements used to build the cabinets. The installation crew knew the dimensions of every piece before it arrived on site. No fit problems required field modification of cabinet components.
Frequently Asked Questions
Why were all three spaces done in a single project?
Coordinating all three spaces in a single project reduced scheduling complexity, allowed hardware and finish decisions to be unified, and produced a single point of accountability for all three installations. It also allowed production to be sequenced so the kitchen, the highest-priority space, was installed first, enabling the kitchen to return to function while office and bathroom installations were completed.
How was the navy bathroom vanity coordinated with the white kitchen & office?
The connection across the three spaces was maintained through consistent door style, shaker throughout, and consistent hardware, the same matte black bar pull profile in appropriate sizes for each space. The navy and white finishes create visual distinction between the spaces while the shared door and hardware language connects them.
Could this project have been done with semi-custom cabinets at a lower cost?
The kitchen dimensions required specific sizing that standard semi-custom widths could not match without fillers. The interior configuration, drawer stacks in five base sections, the specific island dimensions, the appliance garage, required custom specification. The home office built-in required full custom construction for the specific room dimensions. The bathroom vanity required a specific width that fell between standard vanity sizes. In this project, semi-custom could not have delivered the same result at any price point because the specifications were not achievable within standard factory options.
Plan Your Custom Cabinetry Project With D.E. Mitchell Construction
D.E. Mitchell Construction builds and installs fully custom cabinetry in New Bern, Havelock, Morehead City, Jacksonville, and the surrounding Eastern NC communities. We handle kitchen cabinets, bathroom vanities, home office built-ins, mudroom systems, entertainment centers, and any custom woodwork project your home requires.
If you are planning a cabinetry project, in one space or across multiple spaces, reach out and we will schedule a consultation and measurement.
No obligation. No pressure. A direct conversation about what you need built and what it will take to build it right.