Systainer Cabinet Cut List: Carcass, Trays and Sheet Yield
Published by Ahmed Hamade · Woodworker & Cabinetmaker
Generating a clean cut list for a Systainer cabinet requires calculating carcass dimensions, tray margins, slide hardware clearances, and saw blade kerf waste. This guide explains the exact width chain formulas and material accounting rules to ensure high sheet yield in the shop.
Cut List Accounting at a Glance
| Part Group | Standard Material | Nominal Thickness | Kerf Allowance |
|---|---|---|---|
| Carcass Sides, Top, Bottom | Cabinet Grade Plywood | 19 mm (0.75 in) | 3.175 mm (0.125 in) |
| Back Panel | Plywood / MDF | 6 mm or 12 mm | 3.175 mm (0.125 in) |
| Tray Bottoms | Cabinet Plywood | 12 mm (0.47 in) | 3.175 mm (0.125 in) |
| Tray Rims | Solid Hardwood / Plywood | 12 mm (0.47 in) | 3.175 mm (0.125 in) |
1. The Width Chain Formula
Cabinet width is not arbitrary; it is derived from the hardware chain. To calculate the outside carcass width for a SYS3 M cabinet, add each component in series:
Outside Carcass Width = Tray Cavity Width + 2 × Tray Board Thickness + 2 × Slide Clearance + 2 × Carcass Side Thickness
For a SYS3 M case (396 mm wide with 3 mm fit gap per side = 402 mm cavity), 12 mm tray board thickness per side (24 mm total), 12.7 mm slide clearance per side (25.4 mm total), and 19 mm carcass side panels (38 mm total), the resulting outside carcass width is exactly 489 mm (19.25 in).
2. Carcass and Tray Part Calculations
Break down the cabinet into discrete panel components before laying out cuts on full 4x8 ft (1220 mm x 2440 mm) sheet goods.
| Part Description | Width Calculation | Length/Height Calculation |
|---|---|---|
| Carcass Side Panels | Carcass Depth (e.g. 500 mm) | Total Cabinet Height |
| Top and Bottom Panels | Outside Width minus 2x Side Thickness (451 mm) | Carcass Depth |
| Captured Back Panel | Inside Width plus 2x Dado Depth (463 mm) | Inside Height plus 2x Dado Depth |
| Pull-out Tray Bottom | Inside Opening minus 2x Slide Clearance minus 2x Tray Board (402 mm) | Case Depth plus 20 mm Clearance |
3. Edgebanding Allocations and Thickness Deductions
Edgebanding must be accounted for on exposed plywood edges. When using 1 mm or 2 mm thick PVC or wood edgebanding, subtract the edgeband thickness from the raw panel rip width before cutting on the table saw.
You will see the term spelled both ways in the trade. We write it as one word, edgebanding, and you will find the same material sold as edge banding in plenty of supplier catalogs and hardware listings.
Apply edgebanding to the front edge of carcass side panels, carcass top and bottom panels, and the front rim of each tray bottom. Unexposed rear edges and captured dado joints do not require edgebanding.
4. Maximizing Sheet Yield and Reducing Waste
Group panels by material thickness when nesting cuts onto 4x8 ft sheets. Rip long carcass sides first, then cut smaller tray parts from remaining offcuts. Always align grain direction vertically on carcass sides and front-to-back on pull-out trays.
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Frequently Asked Questions
How do I calculate carcass width for a Systainer cabinet?
Add the cavity width (402 mm for SYS3 M with 3 mm fit gap per side), 2x tray board thickness (24 mm for two 12 mm sides), 2x drawer slide clearance (25.4 mm for two 12.7 mm slides), and 2x side panel thickness (38 mm for two 19 mm sides). The outside carcass width equals 489 mm.
How much kerf waste should I account for in a sheet layout?
Standard table saw and CNC router blades cut a 3.175 mm (1/8 in) kerf. Factor this width between every panel when nesting parts on a 4x8 ft sheet.
What thickness is best for Systainer pull-out tray bottoms?
Half-inch (12 mm) cabinet-grade plywood provides high resistance to sagging while keeping total tray weight low. Quarter-inch (6 mm) bottoms are suitable only for lightweight accessory trays.
Should edgebanding thickness be subtracted from part cut dimensions?
If using 1 mm or 2 mm thick edgebanding, subtract the edgeband thickness from the raw panel rip width before cutting. Thin 0.5 mm iron-on edgebanding does not require dimension adjustments in general shop practice.
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