Note: You have left the Costco.com website and are entering the Cabinet website for Costco members sponsored by TuscanHillsKitchensandBaths.com. TuscanHillsKitchensandBaths.com has prepared this site to provide information and estimates for Costco members. To review TuscanHillsKitchensandBaths.com’s Privacy Statement, Read Privacy Policy.
Cabinet Construction Methods
Ultimo® Custom Cabinetry is hand-crafted in America and built to order. Each cabinet is crafted using only the best materials and construction methods and backed by a Lifetime Limited Warranty. Unlike most other cabinet manufacturers, your Ultimo® Custom Cabinetry designer can modify your cabinets in all three dimensions (Height, Depth and Width) to 1/16”. Our cabinetry is built to within 1/16” tolerances, up to 4 times as precise as some competitors.
Ultimo® Box Construction
A) Support Runners 1/2” thick plywood each side for added stability
B) Back Rails 1/2” thick plywood top and bottom for added stability
C) Back Panel 1/4” thick plywood with natural birch melamine interior
D) Adjustable Shelf 3/4” thick plywood surfaced with natural birch melamine, metal shelf pins
E) Bottom 1/2” thick plywood
F) End Panel 3/4” thick plywood
G) Toe Kick 4” tall plywood integrated toe board
H) Face Frame 3/4” thick select solid hardwood
Ultimo® Drawer Construction
Our plywood is specially designed to deliver exceptional durability with a smooth even finish. To achieve this, the plywood used in our exposed finished end panels features a layer of medium density fiber board (MDF) on either side of a hardwood plywood inner core consisting of 3 or more layers of hardwood. MDF is the best surface currently available for the application of tinted varnish, as it delivers a near-perfectly flat surface free from defects. For this reason, tinted varnish is applied directly to the MDF layer. For stained finished ends, stain is applied to a hardwood veneer over the exterior MDF layer. This is an optimal technique as it preserves the beauty of the chosen wood species by preventing the undesirable characteristics of plywood from appearing on the stained surface over time.
Ultimo® Plywood End Panels are Built for Better Results
A) Dovetail Joinery Ensures a strong joint
B) Sides 5/8” thick hardwood for superior strength
C) Routes Routes in the sides hold the bottom ¼” plywood panel tight and “captive”, stapled and glued for extra strength
D) Glides Soft-close, full-extension glides rated to hold 100 lbs.
E) Easy Release Depress button to easily remove drawer for cleaning
Engineered for Better Results
Ultimo® Cabinetry is manufactured with engineered materials as well as natural hardwoods. You will find select hardwoods of the highest quality in the face frames, door frames, and various moldings and trims we manufacture. We do not manufacture hardwood boxes – no cabinetry factory in the world does. Old growth forest, the only type of forest which can be harvested to produce large width boards, is protected – and it should be. Instead, we use that modern marvel – plywood – to construct our cabinet boxes. Other manufacturers will use “plywood ends” but otherwise manufacture their cabinets with particle board, or lesser plywoods like OSB. We do not use these materials in our cabinetry construction.
We do use MDF in some places. Veneer center panel doors like our Brookside door are made with this material. All our finished ends, as described above, will use some of this material as well. In addition, some finished pieces will use this material when structural support is not required. We do not use MDF in the structural construction of our products; MDF is used to enhance the quality of the finish only.
We are open about our use of these materials because we believe you deserve to know how your cabinets are manufactured and why we make the decision to use the materials we use. And we’ll let you in on a secret. If any other cabinetry manufacturer is telling you that they never use these materials, they’re not telling the truth. Everyone uses these materials because they excel at the purposes for which they were invented. Some may tell you “no our cabinetry is all hardwood” and their fine print will indicate that they’re referring to the face frame or some other component, we don’t believe in playing such duplicitous games. We use MDF where it is appropriate in order to make your cabinets as beautiful as modern engineering permits.
As with anything, there are good and bad plywoods, hardwoods, MDFs, etc. You can rest assured that the products we use in our Ultimo® Cabinetry are the highest quality specimens available on the market. As a result, our engineered materials exceed the clean air standards and feature the lowest VOC counts in the industry.
Cabinetry Construction FAQ
What kinds of materials does Tuscan Hills use for cabinet construction?
We use only the highest quality hardwoods, plywood, and engineered materials for cabinet construction. Specifically, all of our bright (non-rustic) hardwoods are FAS (First-and-Seconds) and Selects grade, the highest grade of hardwood lumber which can be purchased on the market. Our plywoods are veneer-core, which means they aren’t made with wood chips or oriented strands but instead with full sheets of hard and softwoods. Some plywoods that we use will have a layer of MDF before the final hardwood veneer, which is a time-consuming and expensive step that significantly enhances the quality and durability of the finish when compared to hard and softwood-only veneer core plywood. We use hard and softwood-only veneer core plywood on cabinets without finished ends as a cost-saving measure over the more expensive MDF-impregnated plywood described above.
Does Tuscan Hills offer “Solid Wood” Doors?
Yes we do. Many door styles will have a “sister” door with an MDF center panel at a less expensive price point, but we offer many of our doors in a hardwood center panel (when stained – when painted maple doors are chosen all center panels are MDF for the highest possible finish quality, see below). These hardwood panels will be constructed of high-quality hardwood staves, glued together and sanded smooth to form a larger panel.
Why don’t Tuscan Hills build their panels out of a single piece of wood?
We get this question often enough that it’s clear someone out there is misinforming potential customers. No one in the world makes cabinets out of single pieces of wood, and if they are, they’re breaking a lot of laws to do it. Consider that a 20” diameter tree of most species would be over 100 years old and would be considered protected old growth forest by responsible governments the world over. Then consider you’d need at least a 30” wide tree to cut a single board wide enough to fit some of our cabinets. Anyone who tells you they make cabinet doors out of a single piece of wood is at best, lying, and at worst destroying the environment for future generations with no appreciable reason for it. We only source our wood from responsibly managed sustainable forestry stands, and plant two trees for every tree we use.
What about so-and-so, they use single pieces of wood?
They do not. You are either looking at a wood veneer, which is very thin and standard in the industry, or you are looking at some type of structured surface – a fabricated man-made wood grain. Some high-end European cabinetmakers will use “book matched” veneers, which are real wood veneers which look fake because the grain matches perfectly. This is a tradition for high-end ultramodern cabinets, and Tuscan Hills sells only high-end traditional style cabinetry, so we do not offer book matching.
What is a tinted varnish?
Tinted varnish is the technical term for our painted finishes. Three tinted coats of catalyzed material are uniformly applied to Maple and Oak cabinetry. Light sanding between coats assures a smooth finish. The finish is oven cured for durability. Tinted varnishes last longer than paint, hold their color better than paint, and get damaged more predictably than paint, which typically peels when damaged. The kinds of dings and dents that accumulate (by themselves according to my kids) over the life of your cabinet are much more easily treated with the provided touch-up materials than painted cabinets are.
What is glazing and when is it a good idea to glaze a door?
Contrary to popular belief, glazing is not a protective top-coat that you pay extra for. A glaze is actually a second color which is applied during the finishing process and is used to accent the woodworking elements of your door. It is applied to the front of the door, and then wiped-off by hand, so that areas of heavily concentrated glaze remain in the nooks and crannies – a technical term called “hang-up.” Because of this, you may not get the full benefit of glazing from a flat slab door or a Shaker door – you’ll see a lot less of the glaze, even though the overall color is hued, because there’s nowhere for the glaze to hang up. It is a good idea to glaze a highly decorative door, as it will highlight those woodworking features.
Do Ultimo cabinets contain any MDF or Engineered materials?
Like other custom cabinetry manufacturers, Ultimo uses engineered hardwoods in some construction applications. Some door styles are made with MDF center panels (these are labeled “veneer recessed center panel” on the website). On the finished end panels of stained cabinets, the MDF veneer is the second-to-last veneer in plywood, with the last (outermost) veneer being the hardwood of your choice. This prevents the telegraphing of any voids in the inner plys from showing through to the finish. For tinted varnish cabinets, the outermost veneer on cabinets with a finished end panel is MDF. This gives the cabinet finish a smooth surface to adhere to and creates a glass-like smoothness and imperfection-free painted finish. Sometimes, if your order contains 5-piece drawer fronts, we include a ¼” hardboard (Masonite) filler to ensure that the drawer front fits snuggly and securely to the drawer box. Some specialty cabinets, like our tambour doors, will be made with engineered material as well, as it is the best available material for the given purpose. None of the stiles and rails on any of our doors come in an MDF or Particle board construction, and our face frames are always made from the hardwood of your choice. MDF will sometimes be used as backers for island panels, depending on your design. It will never be used as a structural component of your cabinetry.
Maple cabinet doors and five-piece headers with a solid center panel finished in a Tinted Varnish and its variations (i.e., painted finishes and glazed painted finishes) will be upgraded to an MDF center panel. MDF is better suited to handle the changes in temperature, humidity or atmospheric pressure that cabinets experience over their lifetime which can cause the finish to crack, the doors to swell or raw wood to be exposed. MDF center panel construction will help mitigate these effects and keep your cabinetry looking pristine longer. This change does not apply to any oak doors, slab doors, stained maple doors or tinted varnish doors with a distressed finish.
Do Ultimo cabinets come with installation screws?
The mounting screws are not included with your cabinetry and should be provided by your installer. We recommend using #8×2.5″ screws and washers. A square socket or torx drive screws are preferred to Philips head, and flat head or washer head screws are ideal. Pre-drilling is not necessary to affix the cabinet through the plywood to the wall, but pre-drilling is necessary for any screwing through every hardwood component of your cabinetry. DO NOT USE SELF-DRILLING SCREWS FOR HARDWOOD APPLICATIONS
How certain can I be that I'll receive the highest quality of cabinetry?
We strive to use only the best components in our cabinetry. Our soft close hinges are manufactured by Blum, the world’s premier operative hardware manufacturer. Likewise, our drawer glides, also made by Blum, have their highest weight rating and smoothest soft close profile available for framed cabinets. We use only veneer core plywood with high grade engineered material to prevent finish defects, with the highest grade exterior veneers for finished ends. Our face frames are cut from FAS & Selects grade hardwood lumber and all our center panel doors use a floating panel technique to help mitigate the effects of thermal expansion and contraction. Every cabinet is measured, cut, and assembled by hand at our factory in South Dakota, inspected, and packaged with care.
For more information, please give us a call today on 1-888-888-7404.