Construct Shaker-Style Doors

10:09

19:20

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What happens here

Calculate the exact dimensions for the stiles (vertical pieces), rails (horizontal pieces), and center panels for each Shaker-style door, accounting for a 2.5-inch width for 1x3 material and deductions for tongue-and-groove joinery (e.g., 20" wide door - 5" (two stiles) - 0.75" (two tongues) = 14.25" for the panel width). Cut the poplar lumber for the stiles and rails to size using a miter saw. Use a 3-piece router bit set on a router table: one bit to create the channel (cope) on the stiles, one bit to create the tenon (stick) on the rails, and a third bit to create the raised or beveled edge on the plywood center panels. Rout all stiles, rails, and panels, ensuring smooth, consistent cuts. Apply wood glue to the tongue and groove joints of the stiles and rails, but *not* to the panel itself, as the panel needs to float freely to accommodate wood movement. Assemble the door components, carefully fitting the panel into the grooved frame. Clamp the assembled door firmly, checking for squareness using a tape measure across diagonals, and allow the glue to cure.

Goal: Precisely cut and rout poplar stiles, rails, and plywood panels, then assemble them into square Shaker-style door frames using wood glue.

Tools and materials

1x3 Poplar Lumber
Clamps (Bar Clamps)
Miter Saw
Plywood Panels (or MDF)
Router Table
Tape Measure
Wood Mallet
Wood Glue

What they say

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three inch one by three uh pieces for the outside frame which is style and rail now this rail part here that's what you have to do a little bit of math so the way we're going to do this is we're going to take our 20 inches and then we're going to subtract five inches why five because one by three the actual number is two and a half inches we're also going to have a little tongue and groove that's on each side three eighths of an inch on each side all we do is subtract .75 putting this at what is that 14 and one quarter and that is going to be the cuts that we do on our miter saw that allow for us to put things on the router so for the raised panels the middle part we're gonna be able to get two out of here i'm gonna rip it all down and get things ready for the router we're ready to start using the router it's a three piece router kit there's piece one this is piece number two it's a different color i know it's a different brand and then number three one creates the styles the channel right in the middle the other creates the rails that's the cross members and then this is a raised panel door which is the middle part it creates a nice little beveled edge so you can go right in the middle [Music] all the styles are done let's do the rails [Music] the real bit's done let's do the panel [Music] not gonna lie though probably one of the most terrifying experiences i've ever had woodworking was using that panel bit it's just so big and when you get the rpms where it's supposed to be it screams we're gonna put the glue on the tongue and groove there i am not gonna put any glue on the inside this has to be able to move expand and contract or else it will warp our door now we have good pressure not too much because you don't squeeze the glue out last thing we need to do is check corner corner folks who have a beautiful door that's a professional grade let's bust some more out [Music] so the door set overnight i'm going to

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