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Making cabinets doors isn’t really such a big deal. Once some basics are understood, the process isn’t so bad. Obviously, you need to have your cabinets drawn out, or maybe even built. Regardless of that, deciding what style of door will work best with your design is pretty much the first decision to be made.
There are a number of styles to choose from. The most basic would be the slab door. So named due to the fact it is just a plain flat piece of material. Usually a piece of plywood or melamine. With these choices, the edges of the door must be covered. The easiest way to hide these raw edges is to use edge banding which is ironed on with a hot iron.
The next door type would be a flat panel door. This consist of a frame, called stiles and rails. The stiles are the vertical pieces, and the rails are the horizontal pieces. We normally make our stiles and upper rails 2 1/4″ wide, and the bottom rail 2 1/2″ wide. Â
These pieces, are joined together with several methods. Pocket screws are becoming a common technique, but there is also biscuits, mortise and tenon joints, or cut on a router table or shaper using a matched cutter set. This is referred to as cope and stick cutters.
The cope and stick set cuts the groove in the edges of the stiles and rails, allowing the panel to fit into this groove.
It is important for the panel to be able to move slightly in this groove, of the door will self destruct, due to expansion and contraction. A product called space balls are often used in the groove, providing a flexible cushion for the movement to occur.
The second cutter shapes, or copes the end of the rails to fit tightly against the stiles, and fit into the groove as well. This makes a nice flat joint, which is quite strong. No fasteners are needed with this type of construction. Just wood glue, and clamps until the glue dries. It is important not to glue the panel in the groove, or the same expansion and contraction problems will occur.
We will often pin, (small brads shot from a pin nailer), or glue the center of the panel in the top and bottom rails, just to keep them from rattling when the doors are closed. It is a good idea to pre-finish the panels if they are made from solid woods, since they movement in the wood can allow the unfinished area of the panel to become exposed. This isn’t as much of a problem when using plywood of other sheet type material since movement from expansion and contraction is minimal.
A more complicated type of panel is the raised panel. These are generally glued up pieces of solid wood, which have the edges shaped to form the raised panel. These panels are then inserted into the stiles and rails. Again, it’s necessary to pre-finish the panel, and not to glue the panel in place. We generally make the panel 1/8″ smaller in both the height and width, allowing the wood to move.
Written by: Lee A Jesberger.
Jesberger has owned of a high end General Contracting business for thirty years.
He also owns and operates a custom Cabinet and Furniture business.
He has written many woodworking articles, in addition to being the inventor of the Ezee-Feed, infeed / outfeed systems for woodworking machines, which is patent pending.
http://www.prowoodworkingtips.com
http://www.myhomewoodshop.com
Copyright 2007 – Lee A. Jesberger. All Rights Reserved Worldwide. Reprint Rights: You may reprint this article as long as you leave all of the links active, do not edit the article in any way, give author name credit.
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