![]() If it can, the panel will rattle in the finished door. The panel should not move into and out of the groove with little friction, but it should not move backward or forward. Advance the cutter into the work piece until the panel just barely fits into the groove. The relief cut on the other side of the panel creates a lip around the panel that fits into the groove on the rails and styles. The relief cut is the one that creates the panel lip. It does not have to be positioned perfectly to produce the desired result. Compared to the rail&stile cutter, the panel cutter is much easier to set up. Make multiple smaller passes around the panel instead of one large one. The panel profile is a dangerous cut due to the high mass of the cutter head. Cut a test piece to make sure everything fits together nicely. The very first setup that produces the gauge block will have to be manual. Simply raise the cutter until it fits into the profile of the gauge block. A gauge block, a piece of wood that has booth profiles milled into it at the correct depth, speeds up this process. The hardest part is the setup of the cutter. The profile along the sides of all stiles and rails is easy to cut. Cut the profile on the stiles and the rails That's why the end cuts must be completed first. It becomes impossible to support the edge with a block of wood. The rail is no longer square on the side. If you cut the side profile first, this method will not work. To combat this problem feed a sacrificial piece through the machine along with the work piece. You will find that tear out is inevitable when a piece is fed through the shaper on its own. Coping sleds can also be shop made with very little effort. Invest in a coping sled if you plan on producing many doors. All other cuts must be made on the correct edge.Ī coping sled or miter gauge helps with this operation. ![]() Once the first cut is made, the work piece has a front and a back. Mind the orientation of the piece and the direction of your cut. Configure the shaper with the correct cutter and run the pieces through on each side. The ends must be cut first due to possible tear out on the edges. The rails, the horizontal pieces, require profiles on each end and one along one side. Take extra care to precisely dimension all parts. Any error in the measurements and the door will not be square. Two rails, two styles, and a panel need to be cut. The gap allows the panel to expand and contract with the seasons.Ĭabinet Door Calculator Next, cut the parts on the table saw This panel fits into a groove that runs along the frame with a 1/8" reveal all around. Simply enter the desired dimensions of the door and the cutting depth of your cutter and the calculator will produce a cut list for. The cabinet door calculator does this for you. Allowances for these joints must be made when designing the door. When assembled the piece lock into each other causing the assembled frame to be slightly narrower than the original pieces suggest. The joints cut on the shaper create locking profiles on the rail and stiles. The rails and stiles need to be correctly dimensioned to create a door of the required width and height. You will very quickly reach the limits of what you can do on a router table. If you want to get into rail&stile door and panel construction you should consider buying a shaper. While doors can be built using a router, the investment in cutters is signifiicant. Multiple passes for each cut will be required. Routers do not posses the power and stability required to drive large panel bits. These should be considered hobbyist quality. Using a routerīoth rail&stile and panel cutters are available for router tables. Make sure the cutter fits into the table opening of your shaper. Panel cutters are amongst the largest shaper cutters available. The panel requires a panel cutter for the profile and a straight cutter for the relief cut on the back. Combination sets produce quality results, but setup takes marginally longer. Cabinet shops often run two shapers to eliminate tool changeovers. Some sets include two entirely separate cutter combinations, while other needs to be reversed to cut the other profile. These cutters will cut two different profiles into the rails and stiles. A multitude of cutters with different profiles are widely available online. The tools needed to build such a door are a table saw to dimension the stock, and a shaper to cut the appropriate profiles in each piece.īesides a good blade for the table saw, you will need a rail&style cutter for your shaper. The ease of construction and high quality results of this method have made it a favorite in cabinet shops. One way to create visually interesting high quality doors is rail and stile construction.
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