Kitchen Hood Surround

Apply glue to the ends of the side aprons with the pocket holes and assemble the apron (Project Diagram, Drawing 1) with pocket-hole screws and clamps.

Apply glue to the pocket-hole ends of the frame sides and assemble the mounting frame (Project Diagram, Drawing 2) with pocket-hole screws and clamps.

Cut the plywood panels for the sides (E) (Project Diagram, Cutting List, and Cutting Diagram). Use a circular saw and a straightedge or a table saw to size the panel. Mark the panel where it needs to be cut and measure the distance from the blade to the edge of the circular saw base. Clamp a board parallel to the marked line on the plywood panel.

Using the board as a guide, push the saw across the panels, pressing the saw base tight against the guide for a straight cut.

Mark the angled cut for the front of the sides (Project Diagram, Drawing 3) and set your saw guide. Make the cut using a circular saw and sand the panels with 150-grit sandpaper.

Drill countersunk pilot holes, and then glue and screw the side panels to the apron sides (B) (Project Diagram, Drawing 3). The bottom edges of the sides should be 4 inches up from the bottom of the apron sides.

Insert the frame into the cabinet and secure to the sides (E) using #8 x 1-1/4-in flathead screws. The bottom edge of the frame should align with the bottom edges of the sides and the back of the frame should be even with the back of the surround.

Set the cleats in position on the panel and drill 5/32-inch pilot holes through the cleats into the slats. The holes should be 2 inches deep.

Set the access panel into the hood surround and secure with clamps. Drill countersunk pilot holes to attach the access panel with stainless-steel screws (Project Diagram, Drawing 6). The front of the cabinet can be easily removed with just two screws after it is installed to gain access to the duct and internal components if maintenance is ever required. Remove the access panel.

Place the access panel on the front of the surround with the cleats (I) fitting between the sides (E). Push the unit up until the top slat reaches the top of the mounting frame. Push the bottom of the panel into the surround so the bottom slat rests on the top edge of the apron front (B) (Project Diagram, Drawing 10).

Secure the access panel to the front of the hood surround with two stainless-steel flathead sheet-metal screws. These screws hold the panel in place, but allow easy access for maintenance.

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