Retrofitting Flap Stays for Mepla Kitchen Cabinets

A flap stay controls the smooth opening and closing of cabinet doors upwards or downwards and reliably holds them in the desired position.

In older, well-built fitted kitchens, moving hardware components experience wear after years of use. When a wall cabinet front fails to stay open on its own or drops uncontrollably when closing, replacing the lifting mechanism is necessary. Anyone looking for replacements for Mepla kitchens often faces the challenge that exact original parts are difficult to source after decades. However, because the furniture industry operates on standardised specifications, modern fittings can easily be used as an alternative to Mepla systems, provided the technical parameters match.

This guide explains the technical criteria for selecting compatible hardware and guides you through the retrofitting process.

What to Consider for Compatibility

To ensure a new fitting is suitable for Mepla wall units, the mounting points and the leverage forces of the front panel must be carefully assessed. The carcasses of most European kitchen manufacturers are built around System 32. This means that pre-drilled hole patterns in the side panels have a centre-to-centre distance of exactly 32 mm. The distance from the front edge of the cabinet to the first row of holes is typically 37 mm.

When retrofitting a flap stay, using this existing hole pattern is ideal. If the spacing aligns, drilling new fixing points into the carcass is unnecessary. For attaching to the front panel (usually made of chipboard or MDF), standard wood screws with a diameter of 3.5 mm or 4 mm are used. Ensure you use the correct drive type—typically PZ (Pozidriv)—to avoid damaging the screw heads during installation.

Opening Direction: Upwards or Downwards?

The mechanism differs fundamentally depending on the movement direction of the front:

• Lift-up stays: The front opens upwards. The hardware must lift the weight of the door and keep it open against gravity.
• Drop-down flap stays: The front opens downwards (e.g. for a drinks cabinet). Here, the fitting must brake the falling motion of the door and lock it in the horizontal position (usually at 90°). The tensile force acts in the opposite direction.

Suitable Replacement Fittings: Mechanical vs. Gas Struts

When selecting compatible components, two technical systems are available, both of which can serve as replacements for Mepla fittings.

Mechanical Friction and Lift-Up Stays

These fittings operate using friction or an integrated steel spring. The resistance can often be continuously adjusted to the weight of the door via an adjustment screw. They require minimal maintenance and are well-suited for light to medium-weight fronts. Some models also work with a cable pull, which mounts very compactly inside the carcass.

Gas Struts

A gas strut (often referred to as a gas spring or gas damper) uses compressed nitrogen gas inside a cylinder. As the piston rod extends or retracts, the gas pressure ensures a smooth, powerful movement. A correctly specified component acts precisely like the damper on a car boot—taking the weight, supporting the upward movement, and softly completing the motion at the end point.

Especially with large wall units featuring heavy fronts, the strength of traditional mechanical stays is often insufficient. This is where gas struts for heavy flaps are used. The force of these cylinders is specified in Newtons (N). Typical ratings for kitchen fronts range between 50 N and 150 N per cylinder.

Tools Required for the Replacement

To remove the old parts and install the new hardware, you will need the following tools:

• Cordless screwdriver or manual screwdriver
• Matching screwdriver bits (usually PZ 2)
• Folding rule or tape measure
• Pencil for marking
• Bradawl or centre punch for new pilot holes

Installation and Retrofitting: Step-by-Step

Replacing a faulty fitting with a compatible alternative requires precision, but is straightforward using standard tools.

1. Removal: Remove the old fitting completely. First detach the connection at the front panel, then the fixing on the carcass. Support the door securely to avoid overloading the hinges.
2. Check dimensions: Measure the centre distance between the old screw holes. Check whether the new fitting shares the same mounting centres.
3. Fit mounting brackets: Attach the new mounting plates or brackets to the carcass interior wall and the front panel. If the hole positions differ, use a bradawl to mark the chipboard lightly. This prevents the screw from wandering.
4. Clip into place: Modern gas struts feature ball joints. Press the cylinder onto the ball stud on the carcass first, then onto the ball stud on the front panel. An audible click indicates that the safety spring has locked into place.
5. Adjustment: Check the opening angle. For mechanical stays, adjust the friction screw so that the flap remains stationary at any angle without dropping.

Kitchen refurbishment tip: While overhauling your wall units, it is often worthwhile to check the base units as well. Sticking drawers can be upgraded with modern kitchen cabinet pull-outs. For standard carcass widths, a kitchen cabinet pull-out 60 cm is ideal. Replacing worn kitchen furniture handles or fitting practical accessories such as a dish drying rack for wall units will also significantly improve the functionality of your existing layout.

Frequently Asked Questions (FAQ)

How do I calculate the required force in Newtons (N) for my gas strut? The force depends on the weight of the front panel (including the handle) and the flap height. As a rule of thumb for standard kitchen fronts (height approx. 300 mm to 400 mm): 1 kg of front weight requires approximately 10 N of spring force. For a 4 kg door, you will need a total of 40 N. Because two struts per flap (left and right) should always be installed to prevent hinge distortion, select two struts rated at 50 N each (the next highest standard rating).

Can I replace a cable-pull stay with a gas strut? Yes, this is generally straightforward and a common method to keep Mepla cabinets fully functional. The main requirement is having sufficient clearance inside the cabinet for the length of the cylinder when closed. Installation dimensions can be found in the technical drawing for the replacement fitting.

Why does my flap not close completely after installing the gas strut? This occurs when the selected force in Newtons is too high for the weight of the door. The cylinder continuously pushes the front slightly upwards. In this case, the gas struts must be replaced with a lower Newton rating. It is not possible to vent or reduce the pressure in sealed furniture gas systems after manufacture.