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Cabinetry: How to Build Raised Panel Doors
Step 1: Draw the plans and double check all measurements
Step 2: Select the wood. Here I'm using Red Oak, 3/4 inch
Step 3: Use Table Saw to Cut the Wood. Some of the wider panels were made by gluing 2 pieces side by side and then sanding with a belt sander.
Various Router Bits -on the left is the "Raised Panel Bit" that makes the center piece of a door. -In the center is a 1" Boring Bit to make the cavity to accept the hinges. -In the rear is one of the Rail & Style bits that make the joint for the sides and top of the door. -In the right rear are the 1//16" and 1/4" Roundover Bits, followed by 1/2" and 1/4" cutting bits -in the front are 3/8" and 1" bits used to make the grooves for opening the doors
Router Table with Rail & Style Bit and plastic "form". The "form" is used to help set up the tool, more specifically to set the exact height needed.
Step 4: Cut Rail and Style Grooves, then Preassemble to check fit
Step 5: With Doors Pre-Assembled, check that Inner piece will fit. Shave as necessary.
Step 6: Using Router on low speed and the big Raised Panel bit, proceed to make a lot of mess (note: I used a fan to keep the router cool during this process)
Step 7: Glue and Assemble all parts. After glue dries, sand the heck out of everything. When working with Oak, don't use anything finer than 100 sand paper otherwise the pores in the wood will close and the stain won't absorb well. Once sanding is completed, pre-hang all doors to make sure that the fit is right. Sand or shave and then re-sand as necessary. Once the hinges are set perfectly, they do not need to be removed from the face-frame. This way when staining is done it will be easy to re-install the doors.
Step 8: 2 Coats of Stain (I used "Golden Oak" by Minwax. Then 4 coats of Minwax High Gloss PolyEurethane, wet sanding inbetween each coat with 400 sandpaper, and 800 on the final sanding. Job complete.
