[DesertRatTom]

Those commercial doors were not made on a router.

Here is a sheet of different styles of bits and the profiles they make. But if you're making doors, you need to get a match set of door making bits. Some of these bits will work for the rails and stiles, but door panels are easier to do with a bit set for doors. Every maker has them. I use Sommerfeld Tools matching bit sets. https://www.fabricdirect.com/shop/c...le-46-unbleached-muslin-fabric-100-yard-roll/ You might also want to watch Marc Sommerfeld's videos on youtube on making panel doors. Really good technique, clear and detailed.

Here is a very simple Shaker style set. Matched sets are best because once you set the first bit, the other or rest are exactly the same shaft length, so you don't have to reset by trial and error. It works by placing a half inch rubber grommet into the bottom of the collet so the shank bottoms out on that grommet. Grommet, not o-ring.

Where it gets more complicated is if you want a raised panel inside the door frame. That requires an additional bit or two, depending on the profile.

The doors you are showing, have been made from glued up strips of solid wood. That gives you the thickness you need to carry the profile from the frame out onto the panel.

 

[DesertRatTom]

I am having a little trouble responding to this because you've posted two completely different types of doors. And the solution for the first (white) is different that the types in the second set of sample doors.

The second set of door pictures are fairly common profiles and you might be able to find a match by looking through some catalogs, either online or in print catalogs. I don't think a bull nose will do what you want.

CMT, Sommerfeld, and a bunch of other companies you'll find online can send you catalogs of bits. There are thousands of different bits, and you might after searching, find one that matches.

However, bit sets are not cheap, and if you can't find a match, you might consider replacing all the doors with commercial or shop made doors. And you might also consider going to a cabinet shop in your area with the door you want to match. and seeing what they can do for you.

But I don't think it's going to be easy reproducing that profile with a router bit.

One last possibility to consider is to have someone, or yourself, make a hand plane iron to the profile, and hand plane enough stock to make a replacement door.

Short of good luck, and a thorough search, or even reproducing the profile to scale and sending copies to all the bit makers, I don't think there is an easy fix. Even if you matched the profile, you still have to match the finish, easier to say than do.

If I had that dilemma, knowing my wife would hound me constantly about the odd door, I'd replace the doors, all of them and be done with it. If you take that route, your bit set will set you back, but you'll also have to buy a fair amount of wood, which you'd have to plane flat and to thickness because big box material is never straight and flat enough to glue up properly, and or use ply for flat panels.

You'll also need jigs to the modern hinges, and forstner bits to drill to mount them. Another expense.

Not meaning to discourage you, but duplicating and matching the other doors is very likely to fail and you'll have a sore thumb door to live with for many years. Here's a site to price cabinet doors by size. Hampton Bay Custom Unfinished Cabinet Door - The Home Depot

 

[DesertRatTom]

Left something out. If you decide to build or match with unfinished commercial doors, then you still have to finish them to go with the other woods in the existing cabinet carcasses. This will almost certainly require having enough extra material to try weveral kinds of stains and finishes on to get the match. I think that would be easier to do if you have a cabinet shop make the doors. They will need a sample to match the finish. You have to at least mach the face frames.

Are you sure you can't salvage the existing problem door? Maybe post a picture of that door we can look at to suggest options?.

 

[DesertRatTom]

So it is the white cbinet you want to match. That's much simpler. I think you can do that with a bead making bit. Like this one that makes 3 beads. You control the number of beads by changing the bit height. Your tape measure covers up come of the corner detail, but I think this is about right. I is also possible since you're only doing one door, that you can use sandpaper on a hand shaped block to perfect the appearance. Again, It will require a bit search.


this.