Custom Deployment · Cabinet Manufacturing

From a 90s-era
order system to a
modern portal—
without losing the database.

Cosmo Cabinets needed a customer-facing order portal that contractors and developers would actually use, but couldn't afford to migrate twenty years of order, pricing, and accrual data out of their legacy MSSQL system. We built the portal on top of it.

Industry
Cabinet Manufacturing
Platform
Custom build · TanStack + MSSQL
Status
Production · Deployed
Database
2020 Insight (MSSQL)
01 / Challenge

Twenty years of orders
locked inside a system
nobody wanted to touch.

Cosmo runs on 2020 Insight — a deep, opinionated MSSQL schema with seven schemas, hundreds of tables, and stored procedures encoding two decades of pricing logic. The legacy customer interface was unusable. Replacing the database wasn't an option. Replacing the experience was.

01
The legacy portal was a non-starter for modern customers. Builders and contractors wouldn't self-serve in it, so every order request bottlenecked through internal staff on the phone.
02
The pricing logic was the business. Decades of price rules, accruals, and feature-grouping logic lived in stored procedures. A rewrite meant re-creating the entire pricing engine from scratch — a multi-year project on its own.
03
Schema landmines everywhere. Default schema isn't dbo — it spans sales, WebOM, WebOrder, Price, OM, ITE. Unprefixed queries fail silently. Most off-the-shelf tools couldn't even introspect it.
04
Customers needed more than orders. Multi-unit projects, truck logistics, attachments, accruals, acknowledgments — every workflow internal staff did manually had to become self-serve.
02 / Solution

A modern portal that
preserves what works,
replaces what doesn't.

We sat on top of the existing Insight database — every table, schema, and stored procedure intact — and built a new TanStack Start portal over it. The pricing engine remained authoritative. The customer experience became modern.

01
Self-serve order creation
Builders create orders with line items, addresses, and attachments. "Save & Get Pricing" hits the legacy stored procedures live, returning the same prices internal staff would quote.
02
Drill-down order detail
Header, lines, addresses, attachments, accruals, pricing — all surfaced from the live database, with parallel fetches and graceful fallbacks if any single query slows down.
03
Multi-unit projects
Phase 2 added project-level workflows: schemes, templates, units, and a 6-step new-project wizard built for developers managing dozens of units across a build.
04
Truck Builder & logistics
Standalone Truck Builder with project integration, plus a logistics overview that lets customers track shipments without calling dispatch.
05
PDF acknowledgments
Save Acknowledgment generates a PDF of the order — group details, pricing, contacts, line items — and posts it directly back to the order's attachments. One-click, audit-ready.
06
Built to be operated
In-memory LRU caching with TTL tuning per query. Eager-connected MSSQL pool. Build-watchdog systemd service. Deploys via GitHub Actions to a single command on the server.
03 / Before · After

What changed
for customers.

Before
Phone the office. Wait. Hope someone calls back.
  • Order status required a phone call to internal staff.
  • New orders entered manually by Cosmo employees on behalf of customers.
  • No self-serve drill-down on attachments, accruals, or accrual counts.
  • Multi-unit projects tracked in spreadsheets and email threads.
  • Truck logistics opaque — customers called dispatch.
  • Acknowledgments printed, signed, scanned, emailed, lost.
After
Log in. See everything. Do everything.
  • Real-time order list with server-side pagination, search, and filters.
  • Customers create their own orders with live pricing from legacy stored procedures.
  • Attachments, accruals, line-level detail — all visible in the portal.
  • Project workspace with units, schemes, templates, and a guided 6-step wizard.
  • Logistics overview with truck-level detail, on-demand.
  • One-click PDF acknowledgments posted back to the order automatically.
04 / Built

By the
numbers.

7
MSSQL schemas
dbo · sales · WebOM · WebOrder · Price · OM · ITE — all queried live
20+
Critical tables & views
Reverse-engineered, mapped, and integrated
0
Data migrated
Legacy database remains the system of record
17
Production routes
Orders, projects, logistics, trucks, profile, auth
50+
Diagnostic scripts
Pricing pipeline, schema extraction, VPN checks, DB comparison
∞
Stored procs preserved
Two decades of pricing logic kept authoritative
05 / Architecture

Modern surface,
legacy spine.

The architecture pattern matters because it generalizes. Every mid-market manufacturer has a legacy ERP they can't replace and a customer experience they can't keep. This is the bridge.

Surface
Customer Portal — TanStack Start + React 19Builders, developers, contractors self-serve; staff supervise instead of transcribe
▼
Bridge
Server functions · Schema-aware query layer · Cache & resilienceEager MSSQL pool, LRU+TTL caching, parallel fetch with per-query fallback
▼
System of record
2020 Insight — MSSQL · 7 schemas · stored procedure pricing engineUntouched. Every order, price, and accrual remains authoritative here
▼
Operations
GitHub Actions · GHCR · Docker · build-watchdog systemdPush to main → image built → deployed to production server, watchdog-monitored
We didn't want a rewrite — we wanted our customers to stop calling us. KyberCore built a portal on top of our existing system that did exactly that, without asking us to throw away twenty years of pricing logic.
Cosmo Cabinets · Production deployment · 2026
06 / Outcomes

What it delivered,
in practice.

01
Customers self-serve, staff escalate.Order entry, status checks, attachments, and acknowledgments moved out of phone calls and into the portal.
Customer experience
02
Two decades of pricing logic, preserved.The legacy stored procedure pipeline is still authoritative — the portal asks it for prices live, never duplicates it.
Risk avoided
03
Multi-unit projects, finally manageable.Developers tracking 30+ units across a build now have a project workspace instead of a spreadsheet graveyard.
Workflow
04
PDF acknowledgments close the loop.One click generates the doc, posts it to the order's attachments, and clears the audit trail. No printing, no scanning, no lost paper.
Compliance
05
A reverse-engineered map of the entire database.Every schema, table, view, and stored procedure documented. Cosmo now owns the institutional knowledge that lived only in the original system.
Knowledge transfer
07 / Why it matters

The Cosmo pattern works for any mid-market manufacturer stuck on a legacy ERP.

Most software vendors look at a 90s MSSQL system and propose a migration. Migrations are how mid-market companies get burned for seven figures and end up with software that's worse than what they started with.

We did the opposite. The legacy system stays. The pricing engine, the order model, the audit history — all preserved. What we built sits on top: a modern portal that makes the existing data accessible, self-serve, and useful.

Cosmo is the deployment that taught us the patterns. Connector resilience, schema-aware querying, parallel fetches with per-query fallback, caching tuned to real workloads — every hard-won lesson from Cosmo became the foundation for MACE, the operating system underneath every KyberCore product going forward.

Have a legacy system
you can't replace?

We've done this once. The second deployment is faster — and we'd like to talk about what's underneath your customer experience.

Start a conversation →Explore KyberCore