How to Build Panel Doors
Panel doors differ from other doors in that they are constructed within the frame while other types of doors are made using one solid piece or wood. They are also called stile or rail doors. Panel doors are hard and sturdy, and since their core is hollow, they are lighter making installation easy and much less expensive than traditional cabinetry.
Things You'll Need:
- Heavy-duty router with variable speeds
- Router table
- Rail and stile bit set
- Back cutter or flat-bottom bit
- Panel glue
- Clamps
- Visit your local hardware store or lumber yard after checking the measurements. You should be aware of the thickness of the wood being used for the frame and it should match with the panel.
- Shape the edges of the panel; be careful not to shave too much wood or the thickness will be reduced.
- Set your stile bit to be used from the inside edge of both rails and stiles. Setting the bit up any other way will affect the strength of the door.
- Make a few test cuts on a few pieces of discarded wood (same thickness) to get the bit depth that will give you the look you desire. For example, if you are using wood that is ¾ inches thick, have a minimum of 3/16 inches between the panel groove and the back of the piece.
- Verify the bit depth. If the depth is incorrect, the rails and stiles will not be properly aligned.
- Size the center panel by measuring the depth of the panel groove against the opening in the dry-assembled frame.
- Clamp the frame and squeeze the joints together.
- Measure the height and width of the opening, then add the groove width to your measurements. Once calculated, subtract the amount of clearance you require. NOTE: if you will be using spacers, please reduce the center panel measurements further. The instructions for this process will be included with the spacers and will define the measurements.
- Back cut the panel so it sits in the frame.
- Apply a thin coat of glue to the rail ends and in the matching area on the stiles. The fit should be very snug. Be sure not to place any glue in the grooves of the panel.
- Clamp the assembled door tight enough to squeeze the joints closed.
- Verify that the door is sitting flat the clamps and allow to dry.