[Jafo9]

@Jafo9,
as Tom says, there are many manufacturers, and you may find the ideal bit. You will need to establish the radius of the bullnose - perhaps you can cut a cross-section from the broken door to show the profile?
My bit cut a deeper groove than yours - 3/16”. A shallower groove would, I guess, permit “thinner” cutting edges on either side of the bullnose.
I dare say you could have a bit modified or custom-made - you guys are blessed with choices in lumber and tooling that the rest of us only dream about. But I also think a custom-made bit could be a bit pricy. Modification would need some skills, as there are small cutting edges at the top and bottom of the bit.
I can’t tell from the photos whether the panel side of the frame is a 90 degree edge, or whether there is a slight bevel.

Please keep us posted as to how you get on.

Just got a quote at $175+ shipping to make a custom bit. It might be worth while to invest; but I’m cheap and want to find a off the shelf solution. Lol

The outer edge is not 90 degrees, more like 5 degree outward on both sides. The bit width is no more than 5/8ths (sorry metric people); the depth of the 1/2” half round is 1/16th in from the face frame.

 

[Jafo9]

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

So many great suggestions. I might just spend the $175+ shipping to have a custom bit made. I’ve been searching and keep coming to the same conclusion; copy the design and tape the bit to the inside of the cabinet door, just in case my kids decide to break another door. Lol

 

[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.

 

[Jafo9]

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

Both doors are the same; with exception of paint/charcoal glaze in the grooves. I found the stained door at Lowe’s which is easier to measure/show the details. I am going to repair the white doors I have already. It’s awful that the doors are no longer made.

 

[Jafo9]

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. View attachment 403661

Yes. I went to woodcraft today and I too was thinking of offsetting it as well. The grooves are much wider and deeper once applied. I was able to go in the back workshop and look at it. Back to the drawing board.

 

[Jafo9]

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.

View attachment 403614

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.

At mlcs they have this finger nail but that looks close, but again the grooves look wide once cut into the material.

 

[Biagio]

Can you not just paint the Lowes door? Are yours custom sizes?
The thumbnail looks too flat, while the bullnose may be too deep.
I think a custom bit may be cheap at the price, especially considering that the sides are not square.
The depth of the bead below the surface is not an issue, you can sink it until the wood rubs up against the shaft of the bit, should you feel so disposed.

 

[Jafo9]

Can you not just paint the Lowes door? Are yours custom sizes?
The thumbnail looks too flat, while the bullnose may be too deep.
I think a custom bit may be cheap at the price, especially considering that the sides are not square.
The depth of the bead below the surface is not an issue, you can sink it until the wood rubs up against the shaft of the bit, should you feel so disposed.

It’s a custom made door, no painting a pre-made door that is a display example. The custom bit is probably the best choice at this point. Unless, there is a router guru that has a better suggestion.

 

[Rebelwork Woodworking]

Even if you match the bit , you have to assemble the doors. My guess is the material is ran through a molder/planer..

 

[Biagio]

You might just, just scrape by with making two parallel cuts with this bit. I could have sworn I had one, went to test it out, and found I don’t have one.

The sides of the groove will be symmetrical, whereas yours are not, but it may not be a noticeable difference once painted.

The problem with the multi-bead bit shown by Tom, is that you would have to rout the bead, then glue it on to the rest of the rail/style material. Otherwise you will not get the square outermost part of the profile.

 

[Jafo9]

You might just, just scrape by with making two parallel cuts with this bit. I could have sworn I had one, went to test it out, and found I don’t have one.
View attachment 403670

The sides of the groove will be symmetrical, whereas yours are not, but it may not be a noticeable difference once painted.

The problem with the multi-bead bit shown by Tom, is that you would have to rout the bead, then glue it on to the rest of the rail/style material. Otherwise you will not get the square outermost part of the profile.

What’s that bit called?

 

[Biagio]

Your part of the world, known as a full bead bit. Lee Valley in Canada has them as beading bits.
‘There is a 3/16 radius option, which should get pretty close to your 5/16 overall bead width. You might have to hand-sand away a fine ridge on the bead, where the two opposing cuts overlap.

 

[Jafo9]

Your part of the world, known as a full bead bit. Lee Valley in Canada has them as beading bits.
‘There is a 3/16 radius option, which should get pretty close to your 5/16 overall bead width. You might have to hand-sand away a fine ridge on the bead, where the two opposing cuts overlap.

I’m going to try a couple of different techniques this weekend and see where it goes. Fingers crossed

 

[Biagio]

Good luck. Keep us posted.

 

[sailer5373]

I need help finding the correct name bit to make this door style:

View attachment 403600
View attachment 403602
View attachment 403601

Looks like a beading bit for the edge.

 

[LouisianaJoe]

You may have to fine tune the depth but try this: Cut a 3/4" dado in the door, cut a 1/2" dowel in half and center it in the dado. Since you are painting it, you will not be able to tell that it is 2 pieces of wood.

 

[Rob Bragg]

I’m making moldings for a door as I respond to this post. I’m using a CNC though to create the shape using a ball nose bit and a molding tool path. If you have access to a CNC it can be recreated.

 

[reuelt]

You might just, just scrape by with making two parallel cuts with this bit. I could have sworn I had one, went to test it out, and found I don’t have one.
View attachment 403670

The sides of the groove will be symmetrical, whereas yours are not, but it may not be a noticeable difference once painted.

Plunge Version may be more useful for a door - not limited to the edge only.

 

[Rob Bragg]

I’m making moldings for a door as I respond to this post. I’m using a CNC though to create the shape using a ball nose bit and a molding tool path. If you have access to a CNC it can be recreated.

 

[Terry Q]

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