In video number 109, Bob Rosendahl shows us how to make something that sounds complicated, but is really easy—panel doors. These can be used for cupboards, a feature wall or even cabinets. Let’s get started.
To make a raised panel door, you will need to have a bit that can make three cuts in one—the cope cut and bead cut. It is a 3-inch bit, which is a bit wider than the normal size bit, but this is fine. Go ahead and put in your bit, then place your base plate back in the table. The base plate should have two holes on either side of the router bit hole so that your fence can line up perfectly, which will automatically set up your distance. Be sure to clamp it down so that it is completely secure. Set your bit height to be at the same level of your materials.
Your door panel kit should include three panels, two long outside pieces (stiles), and run up and down the full length, three rails for the top, bottom and center, and a mullion, which are molded on both sides and make up the space between the two panels. When cut, these should make up the entire panel door. Decide which sides should be your face side and mark them with an “x” in pencil.
Using your push stick, make a cope cut on each end of the rail pieces and the mullion piece, face side down. Without changing the bit, lower the bit to the bead cut bit and make a bead cut, using the push piece again, on the stiles pieces, as well as the top and bottom rail pieces, with a bead cut on one side only; on the mullion and center rail piece, make a bead cut on both sides. Always remember to cut with the grain so that you do not tear out the wood. Each cut piece should fit together nicely when cut. Set aside and it is now time to work on the panels.
Change out the bit to the panel bit and adjust bit for correct height. Take your panel pieces and cut around all the edges, starting on the bottom with the grain, doing the side, then top and other side.
Now you get to put a puzzle together! Put all edge pieces together on the panel pieces, with the stiles on outside, the mullion piece in the middle, the center rail piece between the other two panels and the bottom rail piece. Glue together and enjoy! Click here to join the Router Workshop!!